Using ATL/AFP 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 automated tape laying (ATL) and automated fibre placement (AFP) 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 ATL/AFP laminating production techniques. 

You will be expected to produce a range of mouldings incorporating a variety of features.  Mouldings produced will include laminates using a range of resin and fibres.

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 setup, production activities 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 ATL/AFP 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 to the required specification. 

You will understand the safety precautions required when carrying out the moulding activities and when using 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. confirm what has to be produced and how this will be achieved

3. confirm the material delivery system and equipment have been set up correctly for the ATL/AFP moulding operation
4. check that all safety mechanisms are in place and operate correctly
5. follow the correct component drawing or any other related documentation for the component to be produced
6. carry out any preparation activities required on the tooling, equipment and materials

7. check that the equipment is operating correctly

8. prepare the moulding using the correct methods and techniques

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

10. produce mouldings to the required specification

11. check the quality of the mouldings by visual inspection

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

13. complete relevant documentation
14. 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 ATL/AFP laminating 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, fume/dust extraction systems and equipment)
6. how to identify and use information from engineering drawings and related documentation (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 ATL/AFP laminating techniques (such as material orientation, material identification, ply lay-up, deposition rate, de-bulk factors, bandwidth, tow steering, tensioners, vacuum bagging, cure cycles, exotherm)
10. the safety mechanisms on the ATL/AFP machine and the procedure for checking that they function correctly
11. how to operate the machine controls and how to stop the machine in an emergency
12. the function of the main parts of the ATL/AFP machine (such as drive gear & tracks; deposition heads; material delivery 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 play in the production of mouldings
16. the function fibre materials, fabrics, orientations and their combinations play in the production of mouldings
17. the function core, insert and filler materials play in the production of mouldings
18. how to visually identify raw and finished composite materials
19. how to identify materials by product codes
20. the identification of common defects in production tooling

21. how to prepare patterns, moulds and tooling, including the correct selection and use of surface sealers and release agents

22. the correct methods of storing, thawing and handling of pre-preg materials (including monitoring temperature, storage life and out-life)

23. the correct methods of storing and handling of ancillary and consumable materials
24. how to use ancillary and consumable materials (such as release films, breather fabrics, bagging films, tapes) to meet performance requirements (such as temperature and compatibility)
25. the tools and equipment used in the ATL/AFP laminating activities and their care, preparation and safe handling
26. the common problems that can occur during the lay-up process (including modifications to the ply lay-up and defects such as contamination and distortion)
27. how defects can be prevented during the ATL/AFP laminating activity
28. the cure cycles (including temperature and pressure ramps, dwell times, post curing)
29. the need for monitoring the cure cycle (using thermocouples, probes, chart recorders and data logs)
30. the procedures and methods used for removing mouldings from production tooling
31. the identification of common defects in the composite moulding (such as de-lamination, voids, contaminants)
32. the care and safe handling of production tooling and composite mouldings throughout the production cycle
33. the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
34. 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. check that there are appropriate facilities for storing the completed mouldings (where applicable)
   6. follow safe practice/approved setting and moulding techniques at all times
   7. ensure moulding materials are prepared, loaded and laid up according to the part specification
   8. return all tools and equipment to the correct location on completion of the setting and moulding activities
   9. segregate and dispose of waste materials using the correct procedure 

2. Confirm that the ATL/AFP equipment has be set up correctly to include all of the following:

   1. services are connected and operational (such as electrical, hydraulic, pneumatic, vacuum)
   2. the mould tools are correct, complete, clean and free from damage
   3. the mould tools are correct and securely mounted
   4. all guards, screens and safety mechanisms are in place and in good working order
   5. the equipment tracks are clear and equipment axis move and operate correctly
   6. the deposition head operates correctly
   7. the equipment has been set up to suit the moulding being produced (such as deposition rates, feed rates, heater temperatures, tooling datums, end stop positions, selection of the correct CNC programme), including alarm conditions
   8. the machine controls are operational and function correctly

3. Confirm that the material delivery systems has been set up correctly to include all of the following as applicable to the system being used:

   1. there are sufficient raw materials available and that they meet the component specification (such as resin, fibre, tape/tow width)
   2. that the tape/tow feed systems are operating correctly (such as creels, tensioners, guides, sensors, clamps, cutting heads, compaction rollers, take up reels), where fitted
   3.  the correct pre-catalysed materials has been selected and defrosted where required
   4. the tape/tow materials have been set up correctly on the reels/creels
   5. the pre-preg tape/tow materials have been fed through the correct guides, in sequence to suit the part being produced
   6. the loaded material feed system operates correctly prior to moulding the production part

4. 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

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

   1. obtain correct materials for the activity
   2. thaw material removed from freezer storage
   3. identifying defects in pre-preg materials
   4. check that materials are fit for purpose and in life
   5. confirm availability of ancillary materials required
   6. identify and protect materials in the work area

6. Produce a range of mouldings incorporating a number of the following shape features (three for ATL/five for AFP):

   1. butt joins
   2. overlap joins
   3. staggered joins
   4. localised build-ups
   5. localised cut-outs
   6. joggle details
   7. nett edges
   8. tapered surfaces
   9. single curvature
   10. tubular mouldings
   11. double curvature
   12. female tooling
   13. male tooling
   14. concave surface
   15. convex surfaces
   16. single tow deposition
   17. group tow deposition
   18. variable tow bandwidth
   19. tow steering
   20. other specific feature

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

   1. bio resin
   2. thermoplastic
   3. epoxy
   4. phenolic
   5. bismaleimide
   6. cyanate ester
   7. vinyl ester
   8. other (to be specified)

8. 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)

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

   1. uni-directional tows
   2. unidirectional tapes
   3. woven tapes
   4. multi-axis tapes
   5. thermoplastic powder impregnated fabric
   6. co-mingled thermoplastic fabric
   7. other (to be specified)

10. Produce a range of mouldings using one type of core material (where applicable):

    1. solid timber
    2. end grain balsa
    3. thermoplastic core
    4. rigid foam
    5. syntactic core
    6. expanding core
    7. fibrous honeycomb
    8. aluminium honeycomb
    9. other (to be specified)

11. Use one of the following methods when using core materials (where applicable):

    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

12. Prepare the moulding for temperature curing using one of the following methods:

    1. oven
    2. autoclave
    3. heated tools/moulds
    4. heat mats
    5. heated press
    6. curing lamps
    7. infrared heating
    8. UV curing
    9. electro-magnetic inductance
    10. micro-wave
    11. other (to be specified)

13. Prepare the moulding for pressure consolidation using one of the following methods:

    1. vacuum bags
    2. hot de-bulk
    3. pressure de-bulk
    4. pressure bags
    5. thermal mould expansion
    6. fibre tensioning
    7. press
    8. autoclave

14. Where vacuum bags are used, use two of the following processes/methods:

    1. check vacuum integrity
    2. surface bagging
    3. envelope bagging
    4. multi-part envelope bags
    5. internal bagging
    6. through-tube bagging
    7. pleats and tucks
    8. reusable bagging
    9. use of reusable vacuum fittings

15. Visually inspect a number of 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

16. 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

17. 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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SEMCOMP213

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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; ATL; AFP; Laminating

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