Abstract The present investigation is carried out to assess the suitability of the clinching process for production of plastic–metal hybrid joints. To this end, a prototypal apparatus was developed to preheat the sheets before joining. A campaign of experimental tests was carried out on aluminium alloy AA5053 and polystyrene. Experimental tests were conducted by varying the main process parameters, i.e. pre-heating conditions (heating time and temperature of heating air) and forming pressure. The joints produced under different operating conditions were observed using optical and stereoscope microscope. In addition, the mechanical behaviours of joints were assessed by conducting single lap shear tests on single joints. Based on the achieved results, the main failure modes were identified and the effect of process parameters on mechanical behaviours of the joints were clarified.