This standard identifies the competences you need to produce aircraft composite mouldings by using wet lay-up techniques, in accordance with approved procedures. You will be required to follow the appropriate instructions, drawings, specifications and documentation to produce the composite mouldings, using the correct wet lay-up production techniques.

You will produce a range of composite 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 composite moulding activities undertaken, and to report any problems with the moulding activities, equipment or materials that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will need to ensure that all tools, equipment and materials used in the moulding process are correctly accounted for on completion of the activities, and you must complete all necessary job/task documentation accurately and legibly.

You will be expected to work either with a high level of supervision or as a member of a team, and you will take personal responsibility for your own actions and for the quality and accuracy of the work that you carry out. Where team working is involved, you must demonstrate a significant personal contribution during the team activities in order to satisfy the requirements of this standard, and you must demonstrate competence in all the areas required by the standard.

Your underpinning knowledge will be sufficient to provide a sound basis for your work, and will provide an informed approach to applying the appropriate wet lay-up techniques and procedures. You will understand the production procedures and techniques used, and will know about the tools and techniques, in adequate depth to provide a sound basis for carrying out the activities to the required specification.

You will understand the safety precautions required when carrying out the wet lay-up moulding activities, and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout. You will also understand your responsibilities for safety, and the importance of taking the necessary safeguards to protect yourself and others in the workplace.

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1. work safely at all times, complying with health and safety legislation, regulations, directives and other relevant 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 or laying-up activities using the correct methods and techniques
6. produce components 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

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1. the health and safety precautions to be taken, and procedures used in the specific work area, when working with composite materials, consumables, tools and equipment
2. the hazards associated with carrying out wet lay-up laminating and moulding activities, and with the composite materials, consumables, tools and equipment, and how to minimise these hazards in the work area
3. the protective equipment that is needed for personal protection (PPE) and, where required, the protection of others
4. the application of COSHH regulations in relation to the storage, use and disposal of composite materials and consumables
5. the specific workshop environmental conditions that must be observed when producing aircraft composite mouldings (such as temperature, humidity, styrene levels to threshold limits, fume/dust extraction systems and equipment)
6. how to use and extract information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS or ISO standards), in relation to work undertaken
7. how to interpret and use imperial and metric systems of measurement
8. quality procedures used in the workplace to ensure production control (in relation to currency, issue, meeting specification), and how to complete such documents
9. conventions and terminology used for wet lay-up techniques (including resin and fibre weights/volumes, material orientation, material identification, material tailoring, mixing ratios, gel times, exotherm, bleed plies)
10. the types of resin, fibre and reinforcement used, and their applications
11. the visual identification of both raw and finished composite materials
12. methods of preparation for patterns, moulds and tooling (including the correct use of surface sealers and release agents)
13. mixing ratios for gel coats, resins additives and catalysts, and their associated working times
14. the methods used in the application of the resin/fibre during the lay-up activity
15. tools and equipment used in the lay-up activities, and their care, preparation and control procedures
16. how to recognise faults that can occur during the lay-up process
17. the identification of defects in the composite moulding (such as de-lamination, voids, contaminants)
18. how defects can be overcome during the lay-up activity
19. procedures and methods used for removing mouldings from production tooling
20. the methods and techniques used to trim mouldings, prior to release
21. the care and safe handling of production tooling and composite mouldings throughout the production cycle
22. 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
23. the procedure for the safe disposal of waste materials
24. the recording documentation to be completed for the wet lay-up activities undertaken and, where appropriate, the importance of marking and identifying specific pieces of work in relation to the documentation
25. the extent of your own responsibility, and whom you should report to if you have problems that you cannot resolve

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1. Carry out all of the following during the wet lay-up moulding activities:

   1. ensure that you have the correct documentation for the wet-lay up production operations (such as drawings, job instructions, aircraft standards)
   2. adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations
   3. use the correct tools and equipment for the activity, and ensure that they are safe to use
   4. use the correct materials and consumables, as specified in the production documentation
   5. apply safe and appropriate working practices and procedures at all times
   6. dispose of waste items and materials in a safe and environmentally acceptable manner, in line with company procedures
   7. return all tools and equipment to the correct location on completion of the activities
   8. leave the work area in a safe condition and free from foreign object debris

2. Prepare moulds and materials for the production activities, to include carrying out all of the following:

   1. checking that the tooling is correct and complete
   2. cleaning of tooling and removal of resin build-ups
   3. checking the tooling for surface defects
   4. correctly applying sealants/release agents
   5. obtaining correct materials for the activity
   6. identifying and protecting materials in the work area
   7. dispensing and applying the correct measure and mix of resin/catalyst

3. Produce a range of mouldings, using two of the following application techniques:

   1. spray application of fibre/resin                                  
   2. removal of voids and air pockets
   3. application of a gel coat                                            
   4. use of vacuum bagging
   5. brush application of fibre/resin                                  
   6. use of bleed plies
   7. roller application of fibre/resin

4. Produce a range of mouldings, incorporating one of the following in the lay-up:

   1. feathered joins                                                           
   2. inserts
   3. overlap joins                                                              
   4. fixtures
   5. orientated plies                                                          
   6. butt joins

5. Produce a range of mouldings, incorporating two of the following shape features:

   1. internal corner                                                          
   2. concave surface
   3. external corner                                                         
   4. convex surface
   5. double curvature                                                       
   6. vertical surface

6. Produce a range of mouldings, using all of the following:

   1. resin (such as polyester, epoxy, phenolic, vinyl ester)
   2. fibre (such as glass, carbon, polyethylene, aramid)
   3. reinforcement (such as braids, roving, tapes, chopped strand, continuous filament, woven)
   4. core material (such as wood, coremat, structural foam, honeycomb)

7. Produce a range of mouldings which comply with one of the following standards:

   1. Civil Aviation Authority (CAA)
   2. Ministry of Defence (MoD)                                        
   3. customer standards and requirements
   4. Federal Aviation Authority (FAA)                               
   5. company standards and procedures

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

   1. production documentation                                        
   2. records of equipment settings
   3. quality control documentation                                   
   4. other specific records

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​Additional Information

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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2

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2020

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Current

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Original

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Semta

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SEMAER2-19

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Engineering, Engineering and Manufacturing Technologies, Engineering Professionals, Science and Engineering Technicians

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5234

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Aeronautical; Engineering; composite mouldings; wet lay-up production; laminates and sandwich structures; using a range of resin; fibre and core materials

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