Producing marine components by acrylic moulding

This standard identifies the competences you need to mould acrylics to produce marine components, in accordance with approved procedures. You will be required to use appropriate manufacturing drawings, specifications and documentation to produce the various types of components. You will be expected to produce the acrylic components using the specified/appropriate moulding process and techniques. The equipment will include air-circulating ovens, presses, trimming and automated cutting equipment. The products produced will include deep drawn, double curvature and convex/concave shapes.

Your responsibilities will require you to comply with organisational policy and procedures for the manufacturing activities undertaken, and to report any problems with the acrylic moulding activities, materials or equipment that you cannot personally resolve, or are outside your personal 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 acrylic moulding procedures for marine components. You will understand the moulding procedures, and their application, and will know about the moulding equipment, materials, and consumables used, in adequate depth to provide a sound basis for carrying out the activities to the required specification.

You will understand the safety precautions required when carrying out the moulding operations. 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 done and how this will be achieved
4. obtain and prepare the appropriate tools, equipment and materials
5. carry out the moulding or laying-up activities using the correct methods and techniques
6. produce components to the required specification
7. check that all the required operations have been completed to specification
8. deal promptly and effectively with problems within your control and report those that cannot be solved
9. complete relevant documentation in line with organisational procedures

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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)
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 (PPE) that you need to use for both personal protection and, where appropriate, the 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 procedure for the safe disposal and correct separation of waste materials
6. 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
7. the principles of deep drawing, concave/convex moulding, positive pressure moulding and stress relieving
8. the different methods of heating materials, and the temperature control methods
9. the sheet profiling procedures, and material trimming methods/procedures
10. the supply of acrylic sheet (such as colour, thickness, sheet size, surface texture, material protection)
11. the use of forming aids
12. the methods of sheet trimming and sheet cleaning prior to moulding
13. the preparation methods and procedures applied to the moulding surface
14. the material cleaning methods and procedures to be applied
15. the procedures for de-moulding, and first article inspection (such as test samples, non-destructive testing (NDT) requirements)
16. the quality control procedures to followed during the moulding operations

17. the procedures for ensuring that you have the correct tools and equipment

18. the methods and techniques for lifting, handling and supporting the components/equipment/materials during the moulding activities

19. recognition of moulding defects (such as misalignment, distortion, foreign object damage, contamination and surface defects)
20. the tools and equipment used in the moulding activities, and their calibration, care, preparation and control procedures
21. the problems that can occur with the moulding operations, and how these can be overcome
22. the recording documentation to be completed for the moulding activities undertaken and, where appropriate, the importance of marking and identifying specific pieces of work in relation to the documentation 
23. the extent of your own responsibility 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 acrylic moulding activities:

   1. use the correct issue of drawings, specifications, material data sheets and planning documentation
   2. use copies of relevant COSHH sheets, risk assessment and standards
   3. obtain the tools to be used and check that they are fit for purpose (such as part marked, cleared inspection, undamaged)
   4. return all tools and equipment to the correct location
   5. leave the work area in a safe and tidy condition

2. Obtain the appropriate materials, and carry out all of the following checks:

   1. materials have the correct batch number                
   2. sheet thickness is correct
   3. they are the correct colour                                     
   4. surface texture is correct
   5. the sheet is the correct size                                   
   6. sheets are suitably protected

3. Carry out two of the following moulding methods and techniques:

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

4. Carry out all of the following operations during the moulding process:

   1. tool/equipment preparation                              
   2. stress relieving
   3. setting and controlling temperatures                
   4. sheet forming
   5. sheet preparation                                            
   6. de-moulding
   7. trimming

5. Produce a range of components with four of the following features:

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

6. Produce components which comply with one of the following standards:

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

7. Complete the relevant documentation in line
   with organisational procedures*, *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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Behaviours:

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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3

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29 Apr 2021

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Current

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Original

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Semta

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SEMME3145

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Marine Engineering Trades

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2122

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engineering; marine; produce; components; acrylic moulding; vacuum; deep draw; shape clamping; positive pressure; stress relieving

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