Manufacturing vehicle composite mouldings using wet lay-up techniques

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This standard identifies the competences you need to produce vehicle composite mouldings (body mouldings, structural sections, cover panels, trim panels) using wet lay-up techniques, in accordance with approved procedures. You will be required to use appropriate drawings, specifications and documentation to produce various mouldings using the correct wet lay-up 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 composite mouldings, incorporating a range of features and using a range of application methods. 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 composite moulding wet lay-up 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 produced 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, 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. manufacture vehicle composite mouldings using appropriate methods and techniques
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. manufacture 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
9. ensure that work records are completed, stored securely and available to others as per organisational requirements
10. leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements

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1. the specific safety precautions to be taken whilst carrying out the activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials used)
2. the health and safety requirements of the work area and activities and the responsibility they place on you
3. the hazards associated with the activities, and how to minimise them and reduce any risks

4. the personal protective equipment and clothing (PPE) to be worn during the activities

5. how to extract and use information from engineering drawings and related specifications (to include symbols and conventions to current  industry standards and codes of practice) in relation to work undertaken

6. how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing
7. quality procedures used in the workplace to ensure production control (in relation to currency, issue, meeting specification)
8. conventions and terminology used for wet lay-up techniques (resin and fibre weights/volumes, material orientation, material identification, material tailoring, mixing ratios, gel times, exotherm, bleed plies)
9. the different types of resin, fibre, reinforcement, and their merits
10. the visual identification of both raw and finished composite materials
11. the different types of production tooling used for producing composite mouldings
12. the identification and rectification of defects in production tooling
13. methods of preparation for patterns, moulds and tooling, including the correct use of surface sealers and release agents
14. methods for handling and preparing the reinforcing fibres
15. estimation of resin volume/weight required to wet-out the reinforcing fibres
16. the mixing ratios for gel coats, resins and catalysts, and the associated working times
17. the methods used in the application of the resin/fibre during the lay-up activity
18. the tools and equipment used in the lay-up activities, and their care, preparation and control procedures
19. the problems that can occur during the lay-up process (including defects such as contamination, resin/fibre rich areas, and distortion)
20. how defects can be overcome during the lay-up activity
21. the procedures and methods used for removing mouldings from production tooling
22. the identification of defects in the composite moulding (de-lamination, voids, contaminants)
23. the care and safe handling of production tooling and composite mouldings throughout the production cycle
24. the production controls used in the work area, and actions to be taken for unaccounted items
25. how the composite moulding relates to its own quality documents, and the production tooling used
26. the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
27. how to access, use and maintain information to comply with organisational requirements and legislation

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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, planning and quality control documentation, material data sheets, specifications, )
   2. adhere to procedures or systems in place for risk assessment, hazardous substances , 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 wet lay-up moulding activities
   4. obtain the correct tools and equipment for the activity, and check that they are in a safe, tested and usable condition
   5. follow safe practice/approved wet lay-up moulding techniques and procedures at all times
   6. return all tools and equipment to the correct location on completion of the wet lay-up moulding activities
   7. dispose of waste materials in accordance with approved procedures
   8. leave the work area in a safe and appropriate condition on completion of the activities

2. Prepare production tooling:

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

3. Prepare materials for production:

   1. obtain correct materials for the activity                       
   2. check that quantities of resins are available
   3. check that materials are fit for purpose and `in life'     
   4. identify and protect materials in the work area
   5. cut materials to correct size and shape                      
   6. check correct measure and mix of resin/catalyst

4. Produce a range of mouldings using three of the following application techniques:

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

5. Produce a range of mouldings incorporating two of the following in the lay-up:

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

6. Produce a range of mouldings incorporating three of the following shape features:

   1. internal corners       
   2. double curvatures      
   3. convex surfaces
   4. external corners      
   5. concave surfaces      
   6. vertical surfaces

7. Produce a range of mouldings using techniques for one type of resin from:

   1. polyester     
   2. vinyl ester      
   3. epoxy      
   4. phenolic

8. Produce a range of mouldings using techniques for one type of fibre from:

   1. polyethylene      
   2. glass       
   3. aramid     
   4. carbon

9. Produce a range of mouldings using techniques for two types of reinforcement from:

   1. roving      
   2. braids      
   3. tapes       
   4. chopped strand    
   5. continuous filament     
   6. woven

10. Produce a range of mouldings using techniques for one type of core material from:

    1. wood    
    2. coremat      
    3. foam    
    4. honeycomb

11. Checkmouldings comply with all of the following quality and accuracy standards:

    1. meets company standards and procedures 

    2. dimensionally accurate within specification tolerances

    3. has an appropriate surface finish and is free from defects or surface blemishes

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2

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31 Mar 2023

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Current

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Original

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Semta

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SEMAUT3023

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Engineering, Engineering and Manufacturing Technologies, Science and Engineering Technicians, Vehicle Trades

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5231

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engineering; automotive; manufacturing; vehicle; composite moulds; wet lay-up; resin mould; fibre mould; techniques

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