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Advanced engineered composites are being increasingly in demand to increase the weight-to-strength structural performance of in automobile and aerospace components for reducing fuel consumption and gas emission. Hybrid composites / laminates using light weight metal and plastics are one of the emerging trend to create such structures. The number of methods for controlling the joints of metal and plastic interface in laminate structure have been opened for research. The present study endeavors towards the effect of surface modification of the metal skin on the adhesion strength between metal skin and polymer composite core. A laminate structure with Aluminum skin and epoxy-expanded polystyrene (EPS) composite was developed. The surface modification on the surface of aluminium sheet was done using sand and glass bead blasting at various pressures (3 bar, 4 bar, 5 bar & 7 bar). The effect of blasting pressure and blasting medium on the adhesion strength of the laminate structure wasstudied. The adhesion strength between the laminate structure was observed to be improved at the optimal blasting pressure of 5 bar blasted using SS Sand beeding.