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Lightweight materials such as aluminium alloys, magnesium alloys, and composite material present a significant possibility for applications in automobile and aerospace structures. In order to consider the feasibility of selecting and replacing such materials in the form of hybrid laminated materials, calculations and simulations are investigated with different lightweight materials such as single layer aluminium, fiber-reinforced composite materials, and the aluminium composite laminates, the carbon and glass cloth as the middle layer, under the constant force condition. The stiffness and deflections of these materials are discussed and compared in details. According to calculations, FE and experimental results validate that the deflections and the stiffness of different materials can be predicted well. In order to finalize the material selection, especially for aerospace-based components, the weight ratios are very determinative. Actually, a material with the superior specific stiffness and strength will be the best one considering some other limitations such as corrosion. Calculating the mass ratio of the suggested lightweight materials were done to find an appropriate one. In fact, these kinds of materials have the advantages of both metallic alloys and composites. In addition, in cases where corrosion resistance, environmental protection, fatigue resistance, and impact resistance are needed, FMLs can be the best choice.

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Fiber metal laminates (FMLs) are widely used in manufacturing due to the high specific strength, fatigue resistance, and lightweight. However, because of the deformation coordination of different layers of FMLs, challenges have been faced in rapid and small part forming. To research the feasibility of the fast forming of small parts using the FMLs, the influence of different compositions of FMLs on the stamping performance under the semi-solidified process condition was investigated, including the outer aluminum layer, the fiber lay-up direction in the middle layer, and the various states of the resin. Based on the results of Finite-element simulation and experiments, the semi-solidified process can improve the forming performance of FMLs by making the thickness distribution of the outer aluminum layers more uniform and preventing excessive fiber deformation. The coordination of fiber lay-up direction and interlayer forces can improve the forming limit height of semi-solidified FMLs. Besides, the fracture position of the cup part is related to the fiber lay-up direction and interfacial bonding performance in FMLs. This study provides necessary guidance for the rapid stamp forming of small parts using FMLs.