Modularised wall panels are increasingly used in building and construction. A new double-skin composite (DSC) wall system technology uses clinch seams to combine two roll-formed open section profiles into a hollow steel shell that is then filled with a light-weight concrete foam and can provide a fire-rated DSC solution for use in commercial and high-rise buildings. One important material parameter for the application is the panel performance in wind loading. This study presents a first fundamental analysis of the structural behaviour of the new DSC wall panel relevant to wind loading. For this, 3-point and 4-point bending tests combined with in situ camera analysis are performed and complimented with the analysis of seam strength and the concrete material parameters. The experimental results provide the first experimental evidence that the aerated concrete core material of the DSC panel only has a minor effect on the wall performance in bending. Most of the bending loads are absorbed by the tensile and compressive deformation of the steel outer shell and the shear deformation near the clinch seam. In this way, failure at maximum load is not initiated by concrete cracking but by steel sheet buckling or a mixed failure mode that combines steel buckling and seam opening.

Thermoplastic fibre–metal laminates (FMLs) have great potential for lightweight transportation structures, but continuous forming of complex profiles remains challenging due to the thermo-mechanical incompatibility between metallic skins and thermoplastic composite cores. This study investigates the forming behaviour of thermoplastic fibre-metal laminates (FMLs) for top-hat profile applications using a novel torch-assisted roll forming (TARF) process. The effects of forming speed, roll gap, and laminate architecture on thermal evolution, crystallization behaviour, interfacial integrity, and springback were systematically explored. Real-time temperature monitoring revealed that the forming speed governed the thermo-viscoelastic state of the laminates. Low-speed (LS) forming caused the CF-PA6 matrix to reach its melting point, increasing crystallinity by 30% through longer in-situ annealing time. However, excessive thermal softening resulted in severe flange delamination and localized thinning at the R1 corner. High-speed (HS) forming maintained the laminates in a sub-melting rubbery state, preserving matrix cohesion but causing high residual stresses, significant springback, and interlayer sliding-induced interfacial degradation. The medium-speed (MS) condition provided the optimal processing window. The softened interlayer promoted stress redistribution while maintaining sufficient interfacial cohesion, resulting in no observable macroscopic delamination, interlaminar shear strength (ILSS) retention 65%-93% in the web region. Among all laminate architectures, the Thk0°/90° laminate exhibited the best dimensional stability and interfacial performance, with average springback angles below 1°. This work clarifies the coupled thermal–mechanical deformation mechanisms during warm roll forming of thermoplastic FMLs and provides guidance for high-efficiency manufacturing of lightweight multi-material structures.