Producing composite mouldings using spray lay-up laminating techniques

URN: SEMCOMP305
Business Sectors (Suites): Composite Engineering Suite 3
Developed by: Enginuity
Approved on: 2022

Overview

This standard identifies the competences you need to setup and produce composite mouldings (such as moulds, components, splashes, jigs) using spray 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 correct spray lay-up laminating production techniques.

You will be expected to prepare a range of tooling, apply release agents and prepare composite materials.  You will be expected to setup the spray laminating equipment to produce a range of composite mouldings, incorporating a range 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 setup and production activities undertaken, and to report any problems with the equipment setup, 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 with minimum 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 spray lay-up laminating techniques and procedures.  You will understand the setup and production techniques used, and their application, in adequate depth to provide a sound basis for carrying out the activities, correcting faults, and ensuring the work output is produced to the required specification. 

You will understand the safety precautions required when carrying out the spray lay-up laminating 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.


Performance criteria

You must be able to:

  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. determine what has to be done and how this will be achieved
  4. obtain and prepare the appropriate tools, equipment and materials
  5. set the equipment operating parameters required for the spray lay-up moulding operation
  6. carry out the moulding activities using the correct methods and techniques
  7. check that the equipment operates within the operating parameters set
  8. produce mouldings to the required specification using appropriate methods and techniques
  9. check that all the required operations have been completed to specification
  10. complete and store all relevant documentation in accordance with organisational procedures
  11. deal promptly and effectively with problems within your control and report those that cannot be solved
  12. leave the work area in a safe and appropriate condition on completion of the activities

Knowledge and Understanding

You need to know and understand:

  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 spray lay-up 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 specific environmental conditions that must be observed when producing composite mouldings (such as temperature, humidity, styrene levels to threshold limits, fume extraction systems and equipment)
  5. how to extract and use information from engineering drawings and related specifications (to include symbols and conventions to appropriate standards) in relation to work undertaken
  6. how to interpret drawings/lay-up manuals, imperial and metric systems of measurement, workpiece reference/datum points and system of tolerancing
  7. the quality procedures used in the workplace to ensure production control (in relation to currency, issue, meeting specification) and the completion of such documents
  8. conventions and terminology used for spray lay-up techniques (such as material identification, lay-up specifications, resin viscosity, spray pressure, resin/catalyst ratios, resin and fibre weights/volumes, gel times, exotherm)
  9. the safety mechanisms on the spray and dispensing equipment, and the procedure for checking that they function correctly
  10. the operation of the spray and dispensing equipment, and emergency stop procedures
  11. the parts and functions of the spray and dispensing equipment (to include controls; pneumatic and electricity supplies; material delivery and flushing systems)
  12. the various spray and dispensing equipment operating parameters that may require adjusting prior to spray lay-up moulding activities (such as pressure, flow rate, spray pattern, chopper and chute adjustment, catalyst ratios, fibre ratios), and how these are achieved
  13. the effects that changes to these settings will have on the quality of the components produced
  14. the different types of resins, reinforcement, catalysts, accelerators and additives used, and their applications
  15. the different types of fibre materials and applications
  16. the different core, insert and filler materials, and their applications
  17. the visual identification of both raw and finished composite materials
  18. the different types of production tooling used for producing composite mouldings, and their applications
  19. the identification and rectification of defects in production tooling
  20. methods of preparation for patterns, moulds and tooling (including the correct use of surface sealers and release agents)
  21. methods for handling and preparing the reinforcing fibres
  22. mixing ratios for gel coats, resins and catalysts, and the associated gel times
  23. the spray lay-up methods used during the moulding activity to ensure consistency of deposition
  24. the tools and equipment used in the spray lay-up moulding activities, and their care, preparation and control procedures
  25. the problems that can occur during the spray lay-up process (including defects such as contamination, resin/fibre rich areas, inconsistent deposition)
  26. how defects can be overcome during the spray lay-up activity
  27. the methods and techniques used to trim mouldings prior to release (green trimming)
  28. procedures and methods used for removing mouldings from production tooling
  29. the identification of defects in the composite moulding (such as dry patches, resin rich areas, voids, contaminants)
  30. the care and safe handling of production tooling and composite mouldings throughout the production cycle
  31. the production controls used in the work area, and actions to be taken for unaccounted items
  32. how the composite moulding relates to its own quality documents and the production tooling used
  33. the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve

Scope/range


Scope Performance

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, specifications, equipment setting-up documentation, planning and quality control documentation) 2. adhere to procedures or systems in place for risk assessment, 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 setting and moulding activities 4. obtain and 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. clean/flush resin dispensing and spray equipment after use 7. return all tools and equipment to the correct location on completion of the moulding activities 8. segregate and dispose of waste materials in accordance with approved procedures 2. Prepare the spray and dispensing equipment for use, to include carrying out all of the following: 1. ensure all machine services are connected and operational (such as electrical, pneumatic, feed pipes) 2. ensure there are sufficient raw materials available and that they meet the component specification (such as fibre, resin, catalyst and flushing solvent) 3. set up the machine operating conditions to suit the moulding being produced (such as dispensing pressure/rate, catalyst percentage and alarm conditions) 4. check the spray gun and cleaning cycles function correctly 5. check the chopper unit functions correctly 3. Carry out all 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. fit containment flanges/tooling where required 6. clean and store tooling suitably after use 4. Carry out all of the following activities to prepare materials for production: 1. obtain correct materials for the activity 2. check that materials are fit for purpose and in life 3. check correct quantity of resin is available 4. identify and protect materials in the work area 5. check correct measure and mix of resin/catalyst 5. Carry out all of the following activities to prepare the work area for spray laminating: 1. mask the work area/over spay areas where required 2. ensure adequate ventilation and position fans/extraction where required 3. ensure correct operation of extraction equipment where required 4. check temperature and humidity in the work area are within spray application specifications 6. Setup the spray/chopper gun for use, to include carrying out all of the following: 1. selection of correct spray head size to suit the size and complexity of the moulding 2. adjustment of the spray pressure to obtain a fully developed spray pattern 3. adjustment of the roving feed rate and cutter to meet the required specification 4. adjustment of the chopper chute to ensure to ensure even distribution in the resin stream 7. Produce a range of mouldings using four of the following types of production tool: 1. metal 2. tooling block 3. wet/spray lay-up 4. glass pre-preg 5. carbon pre-preg 6. female tooling 7. male tooling 8. multi-part tools 9. matched tooling 10. closed tooling 11. other specific type 8. Produce a range of mouldings using three of the following application techniques: 1. application of a gel coat 2. spray application of fibre/resin 3. removal of voids and air pockets 4. brush/roller consolidation 5. other specific technique 9. Produce a range of mouldings incorporating seven of the following shape features: 1. internal corner 2. external corner 3. double curvature 4. concave surface 5. convex surface 6. return surfaces 7. joggle details 8. nett edges 9. other specific feature 10. Produce a range of mouldings using one type of resin from: 1. epoxy 2. phenolic 3. bismaleimide 4. cyanate ester 5. other specific type 11. Produce a range of mouldings using techniques for two types of fibre from: 1. polyethylene 2. glass 3. aramid 4. carbon 5. other specific type 12. Produce a range of mouldings using techniques for two types of core material from: 1. wood 2. expanding core 3. syntactic core 4. foam 5. nomex honeycomb 6. aluminium honeycomb 7. other specific type 13. Use four of the following methods/processes when using core materials: 1. core templates 2. pre-shaping core 3. core chamfers 4. core splicing 5. peel plies 6. edge filling 7. adhesive/resin films 8. single stage curing 9. multi stage curing 10. other specific method 14. Produce a range of mouldings which comply with all of the following quality and accuracy standards: 1. company standards and procedures 2. dimensionally accurate within specification tolerances 3. has an appropriate surface finish and is free from defects or surface blemishes

Scope Knowledge


Values


Behaviours


Skills


Glossary


Links To Other NOS


External Links


Version Number

3

Indicative Review Date

2025

Validity

Current

Status

Original

Originating Organisation

Enginuity

Original URN

SEMCOMP305

Relevant Occupations

Engineering, Engineering and Manufacturing Technologies, Engineering Professionals, Science and Engineering Technicians

SOC Code

8114

Keywords

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