Design Optimization of Dissimilar Material Joint Structures using Injection Molding and Structural Analysis

Driven by increasing demands for lightweight and structurally reliable components, studies on metal–plastic dissimilar joints have intensified. This paper proposes a stepwise shape optimization method for an anchor-lock joint combining a metal-additively-manufactured insert and injection molding. Width (W), height (H), and spacing (P) were defined as the design variables, and 27 designs were generated using a design-of-experiments approach. Moldex3D simulations were conducted to evaluate the filling behavior and pressure distribution, identifying geometries with stable molding performance, whereas ANSYS mechanical analyses assessed the total deformation and equivalent stress. The resulting optimal geometry satisfied both molding and structural requirements. Topology optimization was then applied to reduce weight, and the structural performance was maintained after lightweight design, thereby improving design efficiency and enhancing industrial applicability.