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Multi-material solutions offer numerous benefits producing tailored-made hybrid components with enhanced application-optimized properties contrary to conventional monolithic parts. However, designing of corresponding manufacturing processes is often challenging due to various technical aspects. This paper represents a process route for the manufacturing of a hybrid bevel gear by means of tailored forming technology with a focus on die forging and describes the main challenges within the forming stage. Due to local material-specific properties, uncommon material flow and complex geometry of the final part, an individual forming tool system with a geared die was accurately designed. Besides the forming tool system, the FE-based design of the forging process as well as the necessary material characterisation will be presented. Finally, the initial results of the experimental forging investigations are shown.

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