Vacuum forming marine composite materials

This standard identifies the competences you need to vacuum form components, in accordance with approved procedures. You will be required to follow the appropriate instructions, drawings and specifications, to produce the various types of component from thermoplastic sheet, fibre-reinforced thermoplastic sheet and structural foam. This will require you to use a range of air circulating ovens, vacuum forming machines, trimming equipment and various types of tooling. The components produced will have a range of features, including male shapes, female shapes, double curvatures and stiffened mouldings.

Your responsibilities will require you to comply with organisational policy and procedures for the vacuum forming activities undertaken, and to report any problems with the activities, equipment, materials or consumables 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 an understanding of your work, and will provide an informed approach to applying vacuum forming procedures. You will have an understanding of the vacuum forming procedures used, and their application, and will know about the vacuum forming techniques, materials, tooling and consumables used, in adequate depth to provide a sound basis for carrying out the activities, recognising faults and ensuring that the work output is to the required specification.

You will understand the safety precautions required when carrying out the vacuum forming operations 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. confirm that the equipment is set up correctly and is ready for the vacuum forming activities to be carried out
3. operate the machine controls safely and correctly in line with operational procedures
4. produce vacuum formed components to the required specification
5. carry out quality sampling checks at suitable intervals
6. deal promptly and effectively with problems within your control and report those that cannot be solved
7. shut down the equipment to a safe condition on conclusion of the machining activities
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 specific safety practices and procedures that you need to observe when working with vacuum forming equipment (including any specific legislation, regulations/codes of practice for the activities, equipment or materials)
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 carrying out vacuum forming activities, and with the tools and equipment used, and how they can be minimised
5. the application of COSHH regulations in relation to the storage, use and disposal of materials and consumables used in the vacuum forming process
6. how to extract information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS, EN or ISO standards) in relation to the work undertaken
7. how to interpret imperial and metric systems of measurement
8. the methods of sheet trimming and sheet cleaning, prior to forming
9. the preparation methods and procedures applied to the moulding surface
10. the identification of the correct male/female mould tooling
11. the methods and techniques of loading and aligning materials into the mould tooling
12. the methods and techniques for carrying out the de-moulding procedures
13. how to recognise vacuum forming defects (such as misalignment, distortion, damage, contamination and surface defects)
14. the importance of adhering to the vacuum forming cycle
15. the quality control procedures to be followed during the vacuum forming operations
16. the tools and equipment used in the vacuum forming activities, and their care, preparation and control procedures
17. 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
18. the problems that can occur with the vacuum forming operations, and how these can be overcome
19. the production documentation to be completed for the vacuum forming activities undertaken
20. the extent of your own authority, and whom you should report to if you have problems that you cannot resolve

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1. Carry out all of the following during the vacuum forming activities:

   1. use the correct issue of documentation (such as job instructions, drawings, specifications)
   2. use relevant health and safety documentation (such as material data sheets, COSHH sheets, risk assessments)
   3. use the correct materials and consumables, as specified in the production documentation (such as colour, size, composition)
   4. use the correct tools and equipment for the activity, and check that they are fit for purpose
   5. apply safe and appropriate vacuum forming techniques and working practices at all times
   6. leave the work area in a safe and tidy condition
   7. return all tools and equipment to the correct location on completion of the assembly activities

2. Use two of the following types of equipment:

   1. air circulating ovens                         
   2. wood tooling
   3. vacuum forming machines              
   4. trimming equipment
   5. tufnol tooling                                    
   6. composite tooling
   7. metal tooling
   8. other (to be specified)

3. Carry out three of the following operations:

   1. bubble blowing to minimize webbing
   2. positioning of robbers
   3. cleaning of tooling
   4. temperature control
   5. trimming techniques
   6. drying of sheet
   7. use of intensifiers
   8. sheet cleaning
   9. other specific operation

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

   1. double curvatures               
   2. female shapes
   3. male shapes                     
   4. stiffened mouldings
   5. other specific feature

5. Produce a range of components, using one the following materials:

   1. thermoplastic sheet (such as polycarbonate, polysulphone, acrylic, polyvinyl chloride (PVC), ABS)
   2. fibre-reinforced thermoplastic sheet
   3. structural foams (such as polyvinyl chloride (PVC), polymethate (Rohacell)

6. Produce components in accordance 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's standards

7. 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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SEMME2059

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Engineering, Engineering and Manufacturing Technologies

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5235

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Engineering; marine; composite; materials; vacuum; forming; tooling; equipment

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