Abstract: Aluminum alloy (Al)-carbon fiber reinforced polypropylene (CF/PP) hybrid materials can be quickly formed into thin-walled components of the vehicle body by the hot press molding technology, and has broad application prospects in the lightweight design of automobiles. However, the Al mainly exhibits plastic deformation while the CF/PP mainly exhibits fabric tensile/shear deformations during the hot pressing process; In addition, the Al-CF/PP hybrid materials exhibit significant thermo-mechanical coupling characteristics, which bring huge challenges to numerical model developments and hot forming characteristic studies. The 8-layer (Al and CF/PP are alternately and symmetrically laid) Al-CF/PP hybrid hat-shaped rail specimen was prepared by the hot pressing technology, and the fiber angle variations were characterized through the X-ray computed tomography (X-ray CT) layer-by-layer, and the results indicate that the fabrics in Al-CF/PP undergo significant shear deformations; Then, the uniaxial and biaxial tensile experiments were conducted for Al sheets and CF/PP sheets under different temperature conditions, and the temperature-dependent material constitutive model of Al-CF/PP was constructed; And the hot press molding finite element model of the Al-CF/PP hat-shaped rail was developed in ABAQUS, and the predicted fiber angle variations by the simulation are basically consistent with the experimental results. The results indicate that all Al sheets occur thickness reductions, all CF/PP sheets undergo obvious shear deformations and interlayer materials between Al and CF/PP occur significant failure damages during the hot press molding process.