One type of the composite materials is using the metal and polymer together. The resulting hybrid material can offer structural performance which is not independently present in either of the two constituent materials. The major application of the polymer-metal hybrid is in the auto industry with the intention to achieve the desired mechanical properties and weight reduction compared to the traditional all metal solutions.Creating connection between these two layers is an interlock connection type by using surface treatment of metal layer that is in contact with the polymer layer. For creating surface effects on the metal surface layer, laser cladding method is used.Among many technical and economical benefits associated with the use of this method, the high speed and accuracy of the pattern creation on different kinds of the metal surface and the possibility of establishing a variety of the patterns consistent with the type and load directioare the most advantages of this method. By setting the output of powder, speed and power laser, pattern is formed on the surface.In the next step, thermoplastic polymer is injected on the metal surface using an injection molding machine. Tensile residual stresses in the polymer, which leads to shrinkage of the polymer, cause the polymer to grips metal surface. Thus a strong connection between the two layers is formed.Then, the mechanical properties of the hybrid which was produced using this method were numerically and experimentally studied. In order to investigate the hybrid distortion, the tension tensor in different parts of the polymer should be known. Therefore, the polymer injection process was simulated using the MoldFlow commercial software and residual stress tensor was calculated and exported for the next step. Then, ABAQUS software read the data of previous calculation and was used to perform the stress analysis in the polymer-metal hybrid.oth numerical and experimental results show that produced hybrid is bent toward the polymer. The reason is the polymer has a tendency to contract and metal barrier of reducing its length at the junction while the upper parts of polymer shrinkage more. In this research, the effect of metal substrate temperature, injection-molding packing/holding pressure, polymer thickness and pattern covering the surface on the polymer-to-metal adhesive strength, was studied. Thus, 16 experiments based on Taguchi design of experiments were conducted. The results indicate that metal substrate temperature, injection-molding packing/holding pressure, thickness of the injection over-molded cyclic-olefin and pattern covering the surface had the greatest influence respectively. To study and measure the direct effect of the above factors on the bending modulus of the hybrid, 8 three point bending tests in accordance with the array L8 Taguchi were conducted. Factors of polymer thickness, mold temperature, packing pressure and pattern covering the surface had the greatest influence respectively. In the end, according to the results of analytical and practical studies, suggestions for the design of hybrid geometry and condition production requirements piece with the quality were presented. Keywords : Composite material, Polymer to metal adhesion, Laser cladding, Plastic injection molding