Using hand tools to trim composite mouldings

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This standard identifies the competences you need to trim composite mouldings (such as moulds, components, splashes, jigs) using hand tools, in accordance with approved procedures.  You will be required to use appropriate drawings, specifications and documentation to trim various mouldings, using the approved trimming techniques.

You will be expected to use the correct tools and equipment for the trimming activity.  You will trim a range of composite mouldings incorporating a variety of features and using tools and equipment (such as cutting, sanding, drilling and polishing techniques and processes).  Mouldings trimmed will include a range of resin and fibre materials.

Your responsibilities will require you to comply with organisational policy and procedures for the trimming activities undertaken and to report any problems with the trimming 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 composite moulding trimming techniques and procedures.  You will understand the trimming techniques used, and their application, 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 trimming 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 relevant documentation for the moulding to be trimmed
3. check the tools and equipment for the trimming operations are in a safe and usable condition

4. prepare mouldings by marking out, cutting, sanding, drilling and polishing prior to undertaking the trimming operation

5. trim the moulding using the agreed methods and techniques

6. trim moulding to the required specification
7. deal promptly and effectively with problems within your control and report those that cannot be solved
8. complete 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 composite trimming activities, 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 trimming composite mouldings (such as temperature, humidity, fume/dust extraction systems and equipment)
6. the importance of setting up and using dust control measures including segregated work areas, dust extraction, working practices and use of personal protective equipment (PPE)
7. 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
8. how to interpret drawings, lay up manuals, systems of measurement, workpiece reference points and system of tolerancing
9. the quality procedures used in the workplace to ensure production control (in relation to currency, issue, meeting specification) and the completion of such documents
10. the basic conventions and terminology used for trimming activities (such as scribe lines, sanding grades, types of cutting tools, speeds)
11. the types of manual and power tools used, and their applications
12. how the type of material being trimmed can affect the selection of cutting media, tools and speeds
13. the different types of cutting tools and abrasives, and their merits
14. different types of resins, fibres, reinforcement, and their applications

15. how to visually identify cured and non cured composite materials

16. the identification of defects in composite mouldings

17. the different methods used in the trimming of composite mouldings
18. the sequence to be followed when preparing for trimming activities
19. the correct method of handling composite mouldings throughout the trimming activity
20. the importance of ensuring tools and equipment are fit for purpose and safe to use
21. the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
22. the documentation to be completed during and/or on completion of the trimming activity

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

   1. use the appropriate documentation (such as job instructions, drawings, 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. 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
   4. maintain a safe working environment for the composite trimming activities
   5. check that all tools and equipment to be used are in a safe and usable condition
   6. follow safe practice/approved composite trimming techniques and procedures at all times
   7. segregate and dispose of waste materials using the correct procedure
   8. return all tools and equipment to the correct location on completion of the trimming activities 

2. Carry out four of the following activities when preparing for the trimming activity:

   1. check that moulding is correct and complete
   2. check for any defects in the moulding
   3. select the correct equipment for the activity
   4. confirm that the equipment selected is suitable for use
   5. identify and protect the moulding in the work area
   6. confirm the cutting tool and media are suitable for the material being trimmed

3. Mark out mouldings using two of the following :

   1. scriber
   2. height gauge
   3. moulded scribe lines
   4. centre punch
   5. trimming templates
   6. scribing jigs
   7. other (to be specified)

4. Cut mouldings using two the following methods

   1. cutting wheels/discs
   2. saws
   3. routers
   4. trim jigs

5. Sand mouldings using two of the following methods:

   1. rubbing blocks
   2. diamond files
   3. pencil grinders
   4. disc sanders
   5. belt sanders
   6. orbital sander

6. Use a hand drill or pedestal drill to drill mouldings, using one of the following methods:

   1. drill jigs
   2. hole saws
   3. counterbores
   4. countersinks
   5. drill bits
   6. other specified method

7. Polish mouldings using two of the following methods: (where final finish is required)

   1. wet sanding
   2. cutting compound
   3. polishing compound
   4. rubbing block
   5. orbital sander
   6. polisher

8. Trim mouldings using techniques for one of the following resin types:

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

9. Trim mouldings using techniques for one of the following fibre types:

   1. natural fibre
   2. thermo plastic
   3. glass
   4. aramid
   5. carbon
   6. hybrid
   7. other specific types

10. Trim mouldings that require, or incorporate, five of the following features:

    1. straight edges
    2. curved edges
    3. flat surfaces
    4. polished surfaces
    5. shaped surfaces
    6. radius corners
    7. returns
    8. nett edges
    9. joggle details
    10. removal of join lines
    11. multiple holes
    12. multiple hole sizes
    13. countersinks
    14. counterbores
    15. further lay-up stages
    16. inserts to be drilled
    17. inserts to be tapped
    18. solid cores
    19. honeycomb cores
    20. edge filling/sealing
    21. other specified method

11. Trim a range of mouldings in compliance 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

12. 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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SEMCOMP215

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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; hand tools; trim; mark out; drawings; sand; drill; polish

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