Forming marine components by acrylic moulding

This standard identifies the competences you need to produce components by acrylic moulding, in accordance with approved procedures. You will be required to follow the appropriate instructions, drawings, specifications and documentation to produce the various types of component. You will be expected to produce the acrylic components, using the specified moulding process and techniques. This will involve using equipment such as air circulating ovens, presses, trimming and automated cutting equipment. The products produced will include deep drawn, double curvature, convex and concave shapes.

Your responsibilities will require you to comply with organisational policy and procedures for the acrylic moulding activities undertaken, and to report any problems with the 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, 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 be sufficient to provide a sound basis for your work, and will provide an informed approach to applying acrylic moulding techniques and procedures. You will have an understanding of the production techniques used, and their application, in adequate depth to provide a sound basis for carrying out the activities, recognising and correcting/reporting faults, and ensuring that the work output is to the required specification.

You will understand the safety precautions required when carrying out the acrylic 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.

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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 produced and how this will be achieved
4. obtain and prepare the appropriate tools, equipment and materials
5. prepare the acrylic moulding using the correct methods and techniques
6. carry out the acrylic moulding or laying-up activities using the correct methods and techniques
7. produce components to the required specification
8. complete relevant paperwork, in accordance with organisational requirements
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

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1. the specific safety practices and procedures that you need to observe when working with acrylics (including any specific legislation, regulations/codes of practice for the activities, equipment or materials used) 2. the health and safety requirements of the work area where you are carrying out the activities, and the responsibility these requirements place on you 3. the protective equipment that you need to use for both personal protection (PPE) and where appropriate, protection of others 4. the hazards associated with moulding acrylic materials, and with the tools and equipment used, and how they can be minimised 5. the interpretation of drawings, standards, quality control procedures and specifications used for the moulding activity, and how to carry out currency/issue checks of the documents you are working with 6. the principles of deep drawing, concave/convex moulding, positive pressure moulding and stress relieving 7. the different methods of heating materials, and the temperature control methods 8. the sheet profiling procedures, and material trimming methods/procedures 9. the supply of acrylic sheet (such as colour, thickness, sheet size, surface texture, material protection) 10. the use of forming aids 11. the methods of sheet trimming and sheet cleaning prior to moulding 12. the preparation methods and procedures applied to the moulding surface 13. the material cleaning methods and procedures to be applied 14. the quality control procedures to be followed during the moulding operations, and procedures for the completion of such documents 15. the methods and techniques for lifting, handling and supporting the components/equipment/materials during the moulding activities 16. recognition of moulding defects (such as misalignment, distortion, damage, contamination and surface defects) 17. the tools and equipment used in the moulding activities, and their calibration, care, preparation and control procedures 18. why tool/equipment control is critical and what to do if a tool or piece of equipment is unaccounted for on completion of the activities 19. the problems that can occur with the moulding operations and how these can be overcome 20. the recording documentation to be completed for the moulding activities undertaken 21. the extent of your own authority, and whom you should report to if you have problems that you cannot resolve 22. the documentation to be completed during and/or on completion of the forming activity

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

   1. use the correct issue of production documentation (such as job instructions, drawings, specifications, material data sheets, planning and quality control documentation )
   2. use relevant health and safety documentation (such as material data sheets, COSHH sheets, risk assessments)
   3. maintain a safe working environment for the moulding activities
   4. use the correct tools and equipment for the activity, and ensure that they are safe to use
   5. use the correct materials and consumables, as specified in the production documentation
   6. follow safe and appropriate acrylic moulding practices and procedures at all times
   7. return all tools and equipment to the correct location on completion of the moulding activities
   8. segregate and dispose of waste materials using the correct procedure

2. Carry out one of the following acrylic moulding methods and techniques:

   1. vacuum moulding
   2. deep drawing
   3. shape clamping
   4. positive pressure shaping
   5. stress relieving

3. Carry out four of the following operations during the moulding process:

   1. tool/equipment preparation
   2. sheet preparation
   3. trimming
   4. setting and controlling temperatures
   5. stress relieving
   6. sheet forming
   7. de-moulding
   8. other (to be specified)

4. Produce a range of components with two of the following features:

   1. box sections
   2. cylindrical section
   3. convex shapes
   4. concave shapes
   5. single curvatures
   6. double curvatures
   7. other specific feature

5. Produce a range of mouldings, in accordance with one of the following :

   1. BS, ISO or BSEN standards and procedures
   2. customer standards and requirements
   3. company standards and procedures
   4. recognised compliance agency/body's standards

6. Complete the relevant paperwork, to include one from the following and pass it to the appropriate people:

   1. build records
   2. quality/acceptance documentation
   3. system log
   4. job cards
   5. work authorisation documents
   6. other specific reporting method

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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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SEMME2057

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Engineering, Engineering and Manufacturing Technologies

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5235

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Engineering; marine; forming; components; acrylic moulding; vacuum; deep draw; shape; clamping; positive pressure

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