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Producing composite mouldings using resin flow infusion techniques

URN: SEMCOMP306
Business Sectors (Suites): Composite Engineering Suite 3
Developed by: Enginuity
Approved on: 30 Mar 2022

Overview

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This standard identifies the competences you need to produce composite mouldings (such as moulds and components) using resin flow infusion techniques, in accordance with approved procedures.  You will be required to use appropriate drawings, specifications and documentation to produce various mouldings, using the correct resin flow infusion production techniques.  You will be expected to prepare a range of tooling, apply release agents and prepare composite materials.  You will produce a range of mouldings, incorporating a variety of features and using a range of techniques and processes.  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 that are outside your permitted authority, to the relevant people.  You will be expected to work with a minimum of 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 flow infusion 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, correcting faults, 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.

Performance criteria

You must be able to:

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  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. carry out the moulding activities using the correct methods and techniques
  6. produce mouldings to the required specification
  7. check that all the required operations have been completed to specification
  8. complete and store all relevant documentation in accordance with organisational procedures
  9. deal promptly and effectively with problems within your control and report those that cannot be solved
  10. leave the work area in a safe and appropriate condition on completion of the activities

Knowledge and Understanding

You need to know and understand:

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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 flow infusion 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 workshop environmental conditions that must be observed when producing composite mouldings using resin flow infusion techniques (such as temperature, humidity, styrene levels to threshold limits, fume/dust 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 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. the conventions and terminology used for resin flow infusion techniques (such as material orientation, material identification, distribution media, resin viscosity, flow paths, ply lay-up, vacuum bagging, resin and fibre weights/volumes, gel times, exotherm, bleed plies) 9. the different types of resins, reinforcement, catalysts, accelerators and additives used, and their applications 10. the different types of fibre materials, fabrics, orientations, their combinations and applications 11. the different core and insert materials, and their merits 12. the different types of resin distribution media, and their merits 13. the visual identification of both raw and finished composite materials 14. different types of production tooling used for producing composite mouldings, and their applications 15. the identification and rectification of defects in production tooling 16. how to build up laminates (including orientation and balance of plies), to minimise spring and distortion in composite mouldings 17. methods of preparation for patterns, moulds and tooling (including the correct selection and use of surface sealers and release agents) 18. the methods for handling, preparation and application of the reinforcing fibres and fabrics 19. correct methods of storage and handling of ancillary and consumable materials 20. the methods used in the positioning and application of the resin distribution media 21. how to estimate/calculate resin volume/weight required to saturate the reinforcing fibres 22. mixing ratios for gel coats, resins and catalysts, and the associated working times 23. tools and equipment used in the resin flow infusion activities, and their care, preparation and control procedures 24. the operation and importance of a vacuum check before the infusion starts 25. the problems that can occur during the resin flow infusion process (including defects such as contamination, incomplete wet out, vacuum leaks, flow restrictions) 26. the different methods and techniques used to cure composite mouldings including cure cycles and the need for monitoring 27. the procedures and methods used for removing mouldings from production tooling 28. the identification of defects in the composite mouldings (such as de-lamination, voids, contaminants) 29. the care and safe handling of production tooling and composite mouldings throughout the production cycle 30. the production controls used in the work area, and actions to be taken for unaccounted items 31. how the composite component relates to its own quality documents and the production tooling used 32. the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve

Scope/range

Scope Performance

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  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, 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 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 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. Prepare the tooling for production, to include carrying out all 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

  3. Prepare the materials for production, to include carrying out all of the following:

    1. obtain the correct materials for the activity
    2. check that materials are fit for purpose and in life
    3. cut materials to the correct size, shape and orientation
    4. calculate the correct resin to fibre ratios
    5. check correct quantity of resin is available
    6. check the availability of required ancillary materials
    7. identify and protect materials in the work area 
    8. obtain the correct infusion media and layout for the activity

  4. Produce composite mouldings, using three of the following:

    1. test panel trials/tracking
    2. partial trial runs/tracking
    3. full scale trial runs/tracking
    4. production runs
    5. staged resin entry
    6. dry area rectification
    7. vacuum regulation
    8. resin flow regulation
    9. repairs
    10. other specific method

  5. Produce composite mouldings incorporating five of the following in the lay-up:

    1. butt joins
    2. overlap joins
    3. staggered joins
    4. feathered joins
    5. orientated plies
    6. inverted plies
    7. balancing plies
    8. inserts
    9. fixtures
    10. other specific type

  6. Produce composite mouldings incorporating seven of the following shape features:

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

  7. Produce composite mouldings, using techniques for two types of resin from:

    1. polyester
    2. vinyl ester
    3. epoxy
    4. phenolic
    5. bismaleimide
    6. cyanate ester
    7. other specific type

  8. Produce composite mouldings, using techniques for two types of fibre from:

    1. polyethylene
    2. glass
    3. aramid
    4. carbon
    5. other specific type

  9. Produce composite mouldings, using techniques for two types of reinforcement from:

    1. uni-directional
    2. chopped strand
    3. woven
    4. braids
    5. multi-axis/stitched
    6. knitted
    7. tapes
    8. other specific type

  10. Produce composite mouldings, using techniques for three types of core materials from:

    1. wood
    2. expanding core
    3. syntactic core
    4. foam
    5. nomex honeycomb
    6. aluminium honeycomb
    7. other specific type

  11. Produce composite mouldings using techniques for eight types of resin distribution media:

    1. mould surface entry
    2. interlaminar
    3. surface meshes
    4. infusion mats/fabrics
    5. channelled core
    6. perforated core
    7. perforated hose
    8. spiral wrap
    9. peel ply
    10. braid
    11. flow channels
    12. manifolds
    13. networks
    14. bleed plies
    15. moulded vacuum bags

  12. Use six of the following vacuum bagging processes/methods:

    1. check vacuum integrity
    2. surface bagging
    3. envelope bagging
    4. internal bagging
    5. pleats and tucks
    6. reusable bagging
    7. leak detection
    8. leak rectification
    9. catch pots/tanks
    10. localised resin injection
    11. use of reusable vacuum fittings

  13. Produce composite mouldings in compliance 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

31 Mar 2025

Validity

Current

Status

Original

Originating Organisation

Enginuity

Original URN

SEMCOMP306

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; resin flow infusion