Abstract: In the hot press molding process of metal-composite hybrid structures, various defects including fracture, spring-back, delamination, thickness thinning and wrinkle will inevitably occur. Meanwhile fiber yarns in fabric reinforced composites will undergo significant shear deformations with restrictions of blank holding force. The above defects and shear deformations will lead to a significant impact on subsequent structural performances. However, these forming defects of hybrid structures cannot be observed directly during the forming process, and the mechanical cutting method might cause secondary damage to explore these forming defects. More importantly, the damaged specimen cannot be continuously investigated in the subsequent structural performance test, which causes the isolated analysis between forming performance and structural performance and greatly increases the risk of failure. In this study, the hot press molding and three-point bending characteristics of Al-carbon fiber reinforced polypropylene (CF/PP) hybrid hat-shaped rail were studied experimentally. The X-ray computed tomography (X-ray CT) non-destructive test technology was used to investigate the formability of Al-CF/PP hybrid structure on the fiber angle variations, thickness variations, delamination and spring-back deformations, respectively. Moreover, the static three-point bending test was carried out to explore the bending characteristics of the hybrid structure. The results show that the fiber angles convert from orthogonal configurations to non-orthogonal configuration; both thickness increase and thickness reduction occur; delamination occurs significantly around the fillet transition areas; spring-back deformations are unapparent; significant plastic deformations can be found in the bending test and fracturing failures occur in both Al and CF/PP in the end of the test.