The Need

Lightweighting and sustainability goals in transportation and advanced manufacturing are driving interest in bio‑based structural materials. Densified wood (“superwood”) offers metal‑like strength with a renewable feedstock, but its adoption is limited by the lack of robust, manufacturable joining methods to metals. Existing wood joining or adhesive approaches often underperform, lack durability, or are incompatible with high‑volume industrial assembly. A scalable, high‑strength solution for joining densified wood to metals is a critical enabling gap.

The Technology

OSU engineers have developed a hybrid joining method for densified wood and metals using a combination of adhesive bonding and self‑piercing riveting. The approach leverages established automotive manufacturing processes to create strong, damage‑tolerant joints between densified wood and aluminum or other metals. By combining continuous adhesive load transfer with a mechanical fastener, the method achieves high joint strength, improved energy absorption, and reliable performance suitable for structural, multi‑material assemblies.

Commercial Applications

• Automotive body, chassis, and interior structural components
• Aerospace and advanced mobility lightweight structures
• Sustainable multi‑material consumer or industrial products
• Hybrid metal–bio‑composite panels and load‑bearing assemblies

Benefits/Advantages

• Improved damage tolerance and energy absorption versus adhesive‑only joints
• Compatible with existing automotive joining equipment and workflows