Using resin transfer moulding techniques to produce composite mouldings

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This standard identifies the competences you need to produce composite mouldings using resin transfer moulding techniques, in accordance with approved procedures.  You will be required to use appropriate drawings, specifications and documentation to produce various mouldings, using the approved resin transfer moulding production techniques. 

You will be expected to produce a range of mouldings incorporating a variety of features.  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 equipment set up, production activities or materials that you cannot personally resolve, or that 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 resin transfer moulding 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 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. confirm what has to be produced and how this will be achieved
3. confirm the tooling and equipment have been set up correctly for the resin transfer moulding operation
4. follow the correct component drawing or any other related specifications for the component to be produced
5. check that all safety mechanisms are in place and operate correctly
6. carry out any preparation activities required on the tooling, equipment and materials
7. check that the tooling and equipment are operating correctly
8. carry out the moulding activities using the correct methods and techniques

9. produce mouldings to the required specification

10. check the quality of mouldings by visual inspection

11. deal promptly and effectively with problems within your control and report those that cannot be solved

12. complete relevant documentation
13. 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 resin transfer moulding techniques, and with the composite materials, consumables, tools and equipment used, and how to minimise these and reduce any risks in the work area
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, 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 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 resin transfer moulding techniques (such as material identification, lay-up specifications, resin viscosity, injection pressure, injection rate, resin/catalyst ratios, resin and fibre weights/volumes, gel times, exotherm)
10. the safety mechanisms on the machine and the procedure for checking that they function correctly
11. the operation of the machine controls and how to stop the machine in an emergency
12. the function of the main parts of the resin injection machines (such as injector heads, material delivery and flushing systems)
13. the common machine settings that may require adjusting to achieve the required specification
14. the effects that changes to theses settings will have on the quality of the components produced
15. the function resins, reinforcement, catalysts, accelerators and additives play in the production of mouldings
16. the function fibre materials and preforms, their combinations play in the production of mouldings
17. the function core and insert materials play in the production of mouldings
18. how to visually identify raw and finished composite materials

19. the type of production tooling used for producing composite mouldings

20. the identification of common defects in production tooling

21. how to prepare moulds and tooling (including the correct selection and use of surface sealers and release agents)
22. the methods of handling, preparing, positioning the reinforcing fibres and fabrics
23. the importance of having the correct mixing ratios for gel coats, resins, accelerators and catalysts and the associated working times
24. the tools and equipment used in the resin transfer moulding activities and their care and safe handling
25. the common problems that can occur during the resin transfer moulding process (including defects such as contamination, incomplete saturation, pressure/vacuum leaks, flow restrictions)
26. the methods and techniques used to cure composite mouldings including cure cycles and the need to monitor them
27. the procedures and methods used for removing mouldings from production tooling
28. the identification of common defects in the composite mouldings (such as dry patches, print through, voids, contaminants)
29. the care and safe handling of production tooling and composite mouldings throughout the production cycle
30. the actions to be taken for any unaccounted items
31. the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
32. 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, equipment setting-up documentation, 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 setting and 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 setting and moulding techniques at all times
   6. plug injection and vent holes on completion of resin injection where required
   7. clean/flush mixing and injection equipment after use
   8. return all tools and equipment to the correct location on completion of the moulding activities
   9. segregate and dispose of waste materials using the correct procedure 

2. Confirm that the machine has been set up correctly to include all of the following:

   1. all machine services are connected and operational (such as electrical, pneumatic, vacuum)
   2. there are sufficient raw materials available and that they meet the component specification (such as resin, catalyst and flushing solvent)
   3. the machine settings are appropriate for the moulding being produced, including alarm conditions
   4. the injector head and cleaning cycles function correctly
   5. all the machine controls function correctly including pressure and vacuum sensors (where applicable)
   6. the resin and/or mould tool heating arrangements have been set correctly (where applicable)

3. Confirm the machine settings are correct for the moulding activity to include three of the following:

   1. injection pressure
   2. Injection flow rate
   3. injection quantity
   4. catalyst percentage
   5. mould vacuum level
   6. peripheral seal vacuum level

4. Prepare the tooling for production, to include carrying out three 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

5. Produce composite mouldings incorporating four of the following 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
   11. webs/ribs
   12. inserts
   13. fixtures
   14. other specific feature

6. Produce composite 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)

7. Produce composite mouldings, using one type of fibre from:

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

8. Produce composite mouldings, using three types of reinforcement/preform from:

   1. uni-directional
   2. chopped strand
   3. tissues/veils
   4. woven
   5. braids
   6. multi-axis/stitched
   7. tapes
   8. knitted
   9. stitched perform
   10. 3D knitted perform
   11. braided perform
   12. RTM fabric
   13. RTM fabric/core
   14. other (to be specified)

9. Produce composite mouldings, using one type of core materials from:

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

10. Produce composite mouldings, using one type of mould clamping system:

    1. threaded fasteners
    2. toggle clamps
    3. latch clamps
    4. vacuum clamping
    5. hydraulic press
    6. electric press
    7. other (to be specified)

11. Visually inspect a number of sample or trial mouldings and identify two of the following:

    1. mouldings which meet the required specification
    2. mouldings which have defects
    3. mouldings that require further investigation

12. Produce composite mouldings in compliance with one of the following:

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

13. 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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2

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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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SEMCOMP209

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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; resin transfer moulding

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