Producing aircraft composite mouldings using resin flow infusion techniques

This standard identifies the competences you need to produce aircraft composite mouldings (such as moulds and components) using resin flow infusion techniques, in accordance with approved procedures.  It covers both fixed wing and rotary winged aircraft mouldings. You will be required to use appropriate drawings, specifications and documentation to produce various mouldings, using the correct resin flow infusion production techniques. 

You will be expected to prepare a range of tooling, apply release agents, and prepare composite materials.  You will produce a range of mouldings, incorporating a variety of features and using a range of techniques and processes.  Mouldings produced will include laminates and sandwich structures, using a range of resin, fibre and core materials.

Your responsibilities will require you to comply with organisational policy and procedures for the production activities undertaken, and to report any problems with the production activities, equipment or materials that you cannot personally resolve, or that are outside your permitted authority, to the relevant people.  You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying resin flow infusion techniques and procedures.  You will understand the production techniques used, and their application, in adequate depth to provide a sound basis for carrying out the activities, correcting faults, and ensuring that the work output is to the required specification. 

You will understand the safety precautions required when carrying out the moulding activities, and when using the associated tools and equipment.  You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

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1. work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
2. follow the correct component drawing or any other related specifications for the component to be produced
3. determine what has to be done and how this will be achieved
4. obtain and prepare the appropriate tools, equipment and materials
5. carry out the moulding activities using the correct methods and techniques
6. produce mouldings to the required specification
7. check that all the required operations have been completed to specification
8. deal promptly and effectively with problems within your control and report those that cannot be solved
9. leave the work area in a safe and appropriate condition on completion of the activities
10. complete the relevant documentation, in accordance with organisational requirement

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1. health and safety precautions to be taken, and procedures used, when working with aircraft composite materials, consumables, tools and equipment in the specific work area
2. the requirements and importance of understanding and applying human factors as defined by the regulatory requirements and the potential impact if these are not adhered to
3. the hazards associated with carrying out resin flow infusion  techniques, and with the composite materials, consumables, tools and equipment used, and how to minimise these and reduce any risks in the work area
4. protective equipment (PPE) that is needed for personal protection and, where required, the protection of others
5. the application of COSHH regulations in relation to the storage, use and disposal of composite materials and consumables
6. the specific workshop environmental conditions that must be observed when producing composite mouldings using resin flow infusion  techniques (such as temperature, humidity, styrene levels to threshold limits, fume/dust extraction systems and equipment)
7. how to extract and use information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS, ISO or BSEN standards) in relation to work undertaken
8. how to interpret drawings/ lay up manuals, imperial and metric systems of measurement, workpiece reference points and system of tolerancing
9. quality procedures used in the workplace to ensure production control (in relation to currency, issue, meeting specification), and the completion of such documents
10. conventions and terminology used for resin flow infusion  techniques (such as material orientation, material identification, distribution media, resin viscosity, flow paths, ply lay-up, vacuum bagging, resin and fibre weights/volumes, gel times, exotherm, bleed plies)
11. the different types of resins, reinforcement, catalysts, accelerators and additives used, and their applications
12. the different types of fibre materials, fabrics, orientations, their combinations and applications
13. different core and insert materials, and their merits
14. different types of resin distribution media, and their merits
15. the visual identification of both raw and finished composite materials
16. different types of production tooling used for producing composite mouldings, and their applications
17. the identification and rectification of defects in production tooling
18. building up laminates (including orientation and balance of plies), to minimise spring and distortion in composite mouldings
19. methods of preparation for patterns, moulds and tooling (including the correct selection and use of surface sealers and release agents)
20. methods for handling, preparation and application of the reinforcing fibres and fabrics
21. correct methods of storage and handling of ancillary and consumable materials
22. the methods used in the positioning and application of the resin distribution media
23. how to estimate/calculate resin volume/weight required to saturate the reinforcing fibres
24. mixing ratios for gel coats, resins and catalysts, and the associated working times
25. tools and equipment used in the resin flow infusion  activities, and their care, preparation and control procedures
26. why tool/equipment control is critical, and what to do if a tool or piece of equipment is unaccounted for on completion of the activities
27. the operation and importance of a vacuum check before the infusion starts
28. problems that can occur during the resin flow infusion process (including defects such as contamination, incomplete wet out, vacuum leaks, flow restrictions)
29. the different methods and techniques used to cure composite mouldings including cure cycles and the need for monitoring
30. procedures and methods used for removing mouldings from production tooling
31. the identification of defects in the composite mouldings (such as de-lamination, voids, contaminants)
32. the care and safe handling of production tooling and composite mouldings throughout the production cycle
33. the production controls used in the work area, and actions to be taken for unaccounted items
34. how the composite component relates to its own quality documents and the production tooling used
35. the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve

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1. Carry out all of the following during the moulding activities:

   1. obtain and use the appropriate documentation (such as job instructions, drawings, material data sheets, specifications, planning and quality control documentation)
   2. adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
   3. provide and maintain a safe working environment for the moulding activities
   4. obtain and check that all tools and equipment to be used are correct for the operation to be carried out and are in a safe, tested and usable condition
   5. follow safe practice/approved moulding techniques at all times
   6. return all tools and equipment to the correct location on completion of the moulding activities
   7. segregate and dispose of waste materials using the correct procedure

2. Prepare the tooling for production, to include carrying out all of the following:

   1. check that tooling is correct and complete
   2. clean tooling and remove resin build-ups
   3. check for surface defects
   4. correctly apply sealers/release agents
   5. clean and store tooling suitably after use

3. Prepare the materials for production, to include carrying out all of the following:

   1. obtain the correct materials for the activity
   2. check that materials are fit for purpose and in life
   3. cut materials to the correct size, shape and orientation
   4. calculate the correct resin to fibre ratios
   5. check correct quantity of resin is available
   6. check the availability of required ancillary materials
   7. identify and protect materials in the work area
   8. obtain the correct infusion media and layout for the activity

4. Produce composite mouldings, using three of the following:

   1. test panel trials/tracking
   2. partial trial runs/tracking
   3. full scale trial runs/tracking
   4. production runs
   5. staged resin entry
   6. dry area rectification
   7. vacuum regulation
   8. resin flow regulation
   9. repairs

5. Produce composite mouldings incorporating five of the following in the lay-up:

   1. butt joins
   2. overlap joins
   3. staggered joins
   4. feathered joins
   5. orientated plies
   6. inverted plies
   7. balancing plies
   8. inserts
   9. fixtures

6. Produce composite mouldings incorporating seven of the following shape features:

   1. internal corners
   2. external corners
   3. horizontal surface
   4. vertical surface
   5. double curvature
   6. concave surface
   7. convex surfaces
   8. return surfaces
   9. joggle details
   10. nett edges

7. Produce composite mouldings, using techniques for two types of resin from:

   1. bio resin
   2. acrylic
   3. polyester
   4. vinyl ester
   5. epoxy
   6. phenolic
   7. other (to be specified)

8. Produce composite mouldings, using techniques for two types of fibre from:

   1. natural fibre
   2. thermoplastic
   3. glass
   4. aramid
   5. carbon
   6. hybrid
   7. other (to be specified)

9. Produce composite mouldings, using techniques for two types of reinforcement from:

   1. uni-directional
   2. chopped strand
   3. tissues/veils
   4. woven
   5. braids
   6. multi-axis/stitched
   7. knitted
   8. tapes
   9. other (to be specified)

10. Produce composite mouldings, using techniques for three types of core materials from:

    1. solid timber
    2. end grain balsa
    3. coremat
    4. rigid foam
    5. expanding foam
    6. skinned honeycomb
    7. other (to be specified)

11. Produce composite mouldings using techniques for eight types of resin distribution media:

    1. mould surface entry
    2. interlaminar
    3. surface meshes
    4. infusion mats/fabrics
    5. channelled core
    6. perforated core
    7. perforated hose
    8. spiral wrap
    9. peel ply
    10. braid
    11. flow channels
    12. manifolds
    13. networks
    14. bleed plies
    15. moulded vacuum bags

12. Use six of the following vacuum bagging processes/methods:

    1. check vacuum integrity
    2. surface bagging
    3. envelope bagging
    4. internal bagging
    5. pleats and tucks
    6. reusable bagging
    7. leak detection
    8. leak rectification
    9. catch pots/tanks
    10. localised resin injection
    11. use of reusable vacuum fittings

13. Produce mouldings which comply with one of the following standards:

    1. Civil Aviation Authority (CAA)/European Aviation Safety Agency (EASA)
    2. Ministry of Defence (MoD)
    3. Military Aviation Authority (MAA)
    4. Federal Aviation Authority (FAA)
    5. Aerospace Quality Management Standards (AS)
    6. BS, ISO or BSEN standards and procedures
    7. customer standards and requirements
    8. company standards and procedures
    9. manufacturers standards and procedures

14. Complete the relevant paperwork, to include one from the following and pass it to the appropriate people:

    1. build records                 
    2. job cards             
    3. log cards       
    4. aircraft log
    5. other specific recording method

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You will be able to apply the appropriate behaviours required in the workplace to meet the job profile and overall company objectives, such as:

• strong work ethic
• positive attitude
• team player
• dependability
• responsibility
• honesty
• integrity
• motivation
• commitment

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3

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2024

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Current

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Original

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Enginuity

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SEMAE3204

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Engineer, Engineering, Engineering and Manufacturing Technologies, Engineering Technicians

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5234

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Engineering; aeronautical; produce; composite; mouldings; components; laminating; resin; fibre; resin flow infusion

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