Using wet lay-up laminating techniques to produce composite mouldings

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This standard identifies the competences you need to produce composite mouldings (such as moulds, components, splashes, jigs) using wet lay-up laminating techniques, in accordance with approved procedures.  You will be required to use appropriate drawings, specifications and documentation to produce various mouldings using the approved wet lay-up laminating production techniques.

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 are outside your permitted authority, to the relevant people.  You will be expected to work to instructions under 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 wet lay-up laminating 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 and ensuring 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, environmental and other relevant regulations, directives and guidelines
2. follow the correct component drawing or any other related documentation for the component to be produced
3. confirm what has to be produced and how this will be achieved

4. carry out any preparation activities required on the tooling, equipment or materials

5. carry out the moulding activities using the correct methods and techniques

6. produce mouldings to the required specification
7. deal promptly and effectively with problems within your control and report those that cannot be solved

8. complete the relevant documentation 

9. leave the work area in a safe and appropriate condition on completion of the activities

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1. the health and safety precautions to be taken and procedures used when working with composite materials, consumables, tools and equipment in the specific work area
2. the hazards associated with carrying out wet lay-up moulding techniques and with the composite materials, consumables, tools and equipment used and how to minimise these and reduce any risks
3. the protective equipment (PPE) that is needed for personal protection 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 environmental conditions the must be observed when producing composite mouldings (such as temperature, humidity, styrene levels to threshold limits, fume/dust extraction systems and equipment)

6. how to identify 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
7. how to interpret drawings/lay-up manuals, systems of measurement, workpiece reference/datum points and system of tolerancing
8. the quality procedures used in the workplace to ensure production control (in relation to currency, issue, meeting specification) and the completion of such documents
9. the basic conventions and terminology used for wet lay-up techniques (such as resin and fibre weights/volumes, material orientation, material identification, material tailoring, mixing ratios, gel times, exotherm, bleed plies)
10. the function resins, reinforcement, catalysts, accelerators and additives play in the production of mouldings
11. the function fibre materials and fabrics play in the production of mouldings
12. the function core, insert and filler materials play in the production of mouldings
13. how to visually identify raw and finished composite materials
14. the type of production tooling used for producing composite mouldings
15. the identification of common defects in production tooling
16. how to prepare patterns, moulds and tooling (including the correct use of surface sealers and release agents)
17. the procedure for handling and preparing the reinforcing fibres
18. the importance of having the correct resin volume/weight required to wet-out the reinforcing fibres
19. the importance of having the correct mixing ratios for gel coats, resins, accelerators and catalysts, and the associated working times
20. the method used to apply the resin/fibre during the lay-up activity
21. the tools and equipment used in the lay-up activities, their care and safe handling
22. the common problems that can occur during the lay-up process (including defects such as contamination, resin/fibre rich areas and distortion)
23. how defects can be prevented during the lay-up activity
24. the methods and techniques used to cure composite mouldings including cure cycles and the need for monitoring
25. the methods and techniques used to trim mouldings prior to release (green trimming)
26. the procedures and methods used for removing mouldings from production tooling
27. the identification of common defects in the composite moulding (such as de-lamination, voids, contaminants)
28. the care and safe handling of production tooling and composite mouldings throughout the production cycle
29. the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
30. the documentation to be completed during and/or on completion of the moulding activity

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

   1. 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. maintain a safe working environment for the moulding activities
   4. check that all tools and equipment to be used are correct for the operation to be carried out and are in a safe 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. Carry out three of the following activities when preparing production tooling:

   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. Carry out three of the following activities to prepare materials for production:

   1. obtain correct materials for the activity
   2. confirm that materials are fit for purpose and in life
   3. cut materials to correct size and shape
   4. confirm the calculation to obtain the correct resin to fibre ratios
   5. confirm correct quantity of resin is available
   6. identify and protect materials in the work area
   7. confirm correct measure and mix of resin/catalyst

4. Produce a range of mouldings using two of the following types of production tool:

   1. pattern
   2. mandrel
   3. metallic
   4. tooling block
   5. wet lay-up
   6. infused mould
   7. glass pre-preg
   8. carbon pre-preg
   9. female tooling
   10. male tooling
   11. multi-part tools
   12. matched tooling
   13. closed tooling

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

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

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

   1. butt joins
   2. overlap joins
   3. staggered joins
   4. feathered joins
   5. orientated plies
   6. inserts
   7. fixtures
   8. other (to be specified)

7. Produce a range of mouldings incorporating four of the following shape features:

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

8. Produce a range of mouldings using one type of resin from:

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

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

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

10. Carry out the lay-up activities in accordance with two from:

    1. fibre orientation
    2. core orientation
    3. stacking sequence
    4. warp face
    5. fill face
    6. symmetric
    7. asymmetric
    8. callout tables
    9. other (to be specified)

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

    1. uni-directional
    2. roving
    3. chopped strand
    4. continuous filament
    5. tissues/veils
    6. bonded fabrics
    7. woven
    8. braids
    9. tapes
    10. multi axis/stitched
    11. other (to be specified)

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

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

13. Use two of the following methods/processes if using core materials:

    1. core templates
    2. pre-shaping core
    3. core chamfers
    4. core splicing
    5. peel plies
    6. bonding paste
    7. edge filling
    8. adhesive/resin films
    9. single stage curing
    10. multi stage curing

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

    1. BS, ISO or BSEN standards and procedures
    2. customer standards and requirements
    3. company standards and procedures
    4. recognised compliance agency/body standards

15. Complete the relevant documentation, to include one of the following:

    1. production documentation
    2. quality control documentation
    3. job cards

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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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01 Feb 2021

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Current

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Original

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Semta

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SEMCOMP204

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Composite Fitter, Composite Technician, Laminator, Moulding Technician

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8114

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Engineering; produce; composite; mouldings; components; laminating; resin; fibre; wet-lay up

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