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- Joining by forming of lightweight sandwich composite panelsPublication . Contreiras, Tomás R. M.; Pragana, João; Bragança, Ivo; Silva, Carlos; Alves, Luís M.; Martins, PauloThis paper presents a new joining by forming process to assemble longitudinally two metal-polymer sandwich composite panels perpendicular to one another. The process combines sheet-bulk forming with mortise-and-tenon joints to produce mechanically interlocked joints with large and stiff flat-shaped heads. Experimentation and finite element modelling with representative unit cells give support to the presentation and special emphasis is placed on the application of the process to the fabrication of lightweight composite panels for structural applications. Failure of the joints takes place by cracking and not by disassembling after unbending the flat-shaped head of the joint back to its original shape. The required forces to produce the new type of joints are below 15 kN, allowing them to be an easy to implement alternative to existing solutions based on adhesives or fasteners.