Plastic coated steering shaft assembly and laser ablation method of manufacturing

A method of manufacturing a steering shaft assembly comprising:

• applying a plastic material directly to an interface portion of an outer surface of an inner shaft without an intermediate material or agent between the plastic material and the outer surface, wherein the plastic material is not applied with an injection molding process;
• roughening the interface portion with a laser ablation process prior to applying the plastic material directly on the interface portion, wherein the roughness value of the interface portion is equal or greater than 3.5 micrometers;
• and
• positioning the interface portion of the inner shaft within a bore defined by an outer shaft to secure the inner shaft and the outer shaft together, wherein the inner shaft and the outer shaft are formed of metal,
• wherein the laser is a pulsing type of laser that operates with a pulse duration ranging from about 1 femtosecond to 1 millisecond.