Producing composite mouldings using pultrusion techniques
URN: SEMCOMP312
Business Sectors (Suites): Composite Engineering Suite 3
Developed by: Enginuity
Approved on:
30 Mar 2022
Overview
| This standard identifies the competences you need to produce composite mouldings using pultrusion moulding techniques, in accordance with approved procedures. You will be required to use appropriate drawings, specifications and documentation to produce various mouldings, using the correct pultrusion production techniques. You will be expected to prepare material delivery systems and composite materials. You will be expected to setup the pultrusion equipment to produce a range of mouldings incorporating a variety of materials and moulded 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 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 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 pultrusion 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 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:
| 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 pultrusion moulding operation 6. prepare the heating equipment and material delivery system for use 7. check that all safety mechanisms are in place and operate correctly 8. carry out the moulding activities using the correct methods and techniques 9. check that the equipment operates within the operating parameters set 10. produce mouldings to the required specification 11. check that all the required operations have been completed to specification 12. check the quality of the mouldings by visual inspection 13. complete and store all relevant documentation in accordance with organisational procedures 14. deal promptly and effectively with problems within your control and report those that cannot be solved 15. 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 pultrusion 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 the must be observed when producing composite mouldings (such as temperature, humidity, 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 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 pultrusion techniques (such as material identification, pultrusion specifications, resin/catalyst ratios, accelerators, curing temperature, gel time, cure time, exotherm) 9. the safety mechanisms on the machine, and the procedure for checking that they function correctly 10. operation of the machine controls, and how to stop the machine in an emergency 11. the parts and functions of the pultrusion machines (to include machine controls; hydraulic, pneumatic and electricity supplies; die heaters; pulling equipment; cut-off saws; controls; material delivery systems) 12. the various machine operating parameters that may require adjusting prior to pultrusion activities (such as resin/catalyst ratio, pultrusion speed, resin/fibre ratio, moulding temperature), and how these are achieved 13. the effects that changes to theses 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 visual identification of both raw and finished composite materials 16. the identification of defects in production tooling 17. methods for handling, preparation and application of the reinforcing fibres and fabrics 18. the tools and equipment used in the pultrusion activities, and their care, preparation and control procedures 19. the problems that can occur during the pultrusion process (including defects such as contamination, exotherm, resin rich, dry fibres, broken tows, incomplete curing) 20. the identification of defects in the composite mouldings (such as porosity, contaminants, dry fibres, tension variation, fibre separation) 21. the care and safe handling of mandrel tooling and composite mouldings throughout the production cycle 22. the production controls used in the work area, and actions to be taken for unaccounted items 23. how the composite component relates to its own quality documents and the production tooling used 24. 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. ensure 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 and in sequence 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. Prepare the pultrusion machine for use, to include carrying out all of the following: 1. ensure all services are connected and operational (such as electrical, hydraulic, pneumatic) 2. check the moulding dies are correct, complete, clean and free from damage 3. ensure the moulding dies are correct and securely mounted 4. ensure that all guards, screens and safety mechanisms are in place and in good working order 5. ensure the profile pullers operate correctly 6. ensure the flying cut-off saw operates correctly 7. set up the profile pullers and cut-off saw operating conditions to suit the profile being produced (such as linear speeds, transverse speeds, end stop positions), including alarm conditions 8. check that all the machine controls are operational and function correctly 3. Prepare the material delivery systems, to include carrying out all of the following where applicable: 1. ensure there are sufficient raw materials available and that they meet the component specification (such as resin, catalyst, additives, fibres) 2. set and check that the resin/catalyst feed and mixing systems are operating correctly (such as collection tubes, mixing heads, dispensing heads/injectors), where fitted 3. correctly select, remove from freezer and defrost pre-catalysed materials where required 4. correctly set up fibre materials on racks/creels as required and apply splice joins as required 5. feed the fibres through the correct guides in sequence to suit the part being produced 4. Prepare the die heating equipment for use, to include carrying out all of the following where applicable: 1. ensure all heating services are connected and operational (such as electrical, fluids, steam) 2. set up the process heating conditions to suit the moulding being produced (such as zones, temperature, pressure, rates), including alarm conditions 3. conduct a mould surface temperature survey and adjust heating general and local heating parameters accordingly 4. check that all the heating controls are operational and function correctly 5. Prepare the heating equipment for use, to include three of the following: 1. heated platterns 2. in-mould heating 3. electric heating 4. water heating 5. steam heating 6. oil heating 7. electro-magnetic inductance 8. micro-wave 9. other specific method 6. Produce composite mouldings using five of the following features: 1. sharp corners 2. radius corners 3. horizontal surfaces 4. vertical surfaces 5. curved surfaces 6. corrugated surfaces 7. solid section 8. hollow section 9. longitudinal recesses 10. longitudinal webs/ribs 11. undercuts 12. longitudinal inserts 13. other specific feature 7. Produce composite mouldings, using one type 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 two types of fibre from: 1. polyethylene 2. glass 3. aramid 4. carbon 5. other specific type 9. Produce a range of mouldings using four types of reinforcement from: 1. uni-directional tows 2. unidirectional tapes 3. woven fabrics 4. multi-axis fabrics 5. pre-impregnated tows/tapes 6. thermoplastic powder impregnated fabric 7. co-mingled thermoplastic fabric 8. fabric preform 9. other specific type 10. 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 11. 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
SEMCOMP312
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; pultrusion