With the wide application of lightweight materials, the metal–polymer multilayer structure has become a research focus owing to the advantages of lower weight and higher vibration damping. In the current work, the mechanical clinching process of the metal–polymer multilayer structure between Al5052-H32 and polyoxymethylene was investigated. The effect of diverse plate configurations and different test specimen forms on the mechanical characteristics was analysed in terms of geometric parameters, static strength, failure modes and energy absorption. The results showed that the metal–polymer multilayer structure could be successfully connected utilizing the mechanical clinching process. The cross-tension load and lap-shear load of the joint were greatly affected by the plate configuration as well as the test specimen form.
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