Producing composite mouldings using wet lay-up techniques
Overview
This standard identifies the competences you need to produce composite mouldings (such as moulds, components, splashes, jigs) using wet lay-up techniques, in accordance with approved procedures. You will be required to follow the appropriate instructions, drawings, specifications and documentation to produce the composite mouldings, using the correct wet lay-up production techniques.
You will produce a range of composite mouldings, incorporating a range 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 composite moulding activities undertaken, and to report any problems with the moulding 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 good understanding of your work, and will provide an informed approach to applying composite moulding wet lay-up 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 faults, and ensuring the work output is to the required specification.
You will understand the safety precautions required when carrying out the wet lay-up 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:
P1 work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
P2 follow the correct component drawing or any other related specifications for the component to be produced
P3 determine what has to be done and how this will be achieved
P4 obtain and prepare the appropriate tools, equipment and materials
P5 carry out the moulding or laying-up activities using the correct methods and techniques
P6 produce mouldings to the required specification
P7 deal with problems within your control and report those that cannot be solved
P8 check that all the required operations have been completed to specification
P9 complete and store all relevant documentation in accordance with organisational requirements
Knowledge and Understanding
You need to know and understand:
K1 how to work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
K2 the importance of wearing the appropriate personal protective equipment (PPE), and of keeping the work area clean and tidy
K3 the application of COSHH regulations in relation to the storage, use and disposal of composite materials and consumables
K4 the specific environmental conditions that must be observed when producing composite mouldings
K5 how to extract and use information from engineering drawings and related specifications in relation to work undertaken
K6 how to interpret and use imperial and metric systems of measurement
K7 quality procedures used in the workplace to ensure production control
K8 conventions and terminology used for wet lay-up techniques
K9 the type of resin, fibres and reinforcement used, and their applications
K10 the function resins, reinforcement, catalysts, accelerators and additives play in the production of mouldings
K11 the function fibre materials and fabrics play in the production of mouldings
K12 the function core, insert and filler materials play in the production of mouldings
K13 the visual identification of both raw and finished composite materials
K14 methods of preparation for patterns, moulds and tooling
K15 mixing ratios for gel coats, resins and catalysts, and their associated working times
K16 the methods used in the application of the resin/fibre during the lay-up activity
K17 tools and equipment used in the lay-up activities, and their care, preparation and control procedures
K18 how to recognise issues that can occur during the lay-up process
K19 the methods and techniques used to cure composite mouldings including cure cycles and the need for monitoring
K20 the methods and techniques used to trim mouldings prior to release
K21 procedures and methods used for removing mouldings from production tooling
K22 the identification of defects in the composite moulding
K23 the care and safe handling of production tooling and composite mouldings throughout the production cycle
K24 the production controls used in the work area, and actions to be taken for unaccounted items
K25 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:
1.1 obtain and use the appropriate documentation (such as job instructions, drawings, quality control documentation, material data sheets)
1.2 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
1.3 obtain the correct tools and equipment for the activity and ensure they are safe to use
1.4 use the correct materials and consumables, as specified in the production documentation
1.5 apply safe and appropriate wet lay-up working practices and procedures at all times
1.6 return all tools and equipment to the correct location on completion of the moulding activities
1.7 segregate and dispose of waste materials using the correct procedure
1.8 leave the work area in a safe and appropriate condition on completion of the activities
2 Carry out three of the following activities when preparing production tooling:
2.1 check that tooling is correct and complete
2.2 clean tooling and remove resin build-ups
2.3 check for surface defects
2.4 correctly apply sealers/release agents
2.5 clean and store tooling suitably after use
3 Carry out three of the following activities to prepare materials for production:
3.1 obtain correct materials for the activity
3.2 confirm that materials are fit for purpose and in life
3.3 cut materials to correct size and shape
3.4 confirm the calculation to obtain the correct resin to fibre ratios
3.5 confirm correct quantity of resin is available
3.6 identify and protect materials in the work area
3.7 confirm correct measure and mix of resin/catalyst
4 Produce a range of mouldings using two of the following types of production tool:
4.1 pattern
4.2 mandrel
4.3 metallic
4.4 tooling block
4.5 wet lay-up
4.6 infused mould
4.7 glass pre-preg
4.8 carbon pre-preg
4.9 female tooling
4.10 male tooling
4.11 multi-part tools
4.12 matched tooling
4.13 closed tooling
5 Produce a range of mouldings using two of the following application techniques:
5.1 spray application of a gel coat
5.2 brush application of a gel coat
5.3 spray application of fibre/resin
5.4 brush application of fibre/resin
5.5 roller application of fibre/resin
5.6 removal of voids and air pockets
5.7 brush/roller consolidation
5.8 use of vacuum bagging
5.9 use of bleed plies
6 Produce a range of mouldings incorporating two of the following in the lay-up:
6.1 butt joins
6.2 overlap joins
6.3 staggered joins
6.4 feathered joins
6.5 orientated plies
6.6 inserts
6.7 fixtures
7 Produce a range of mouldings incorporating four of the following shape features:
7.1 internal corner
7.2 external corner
7.3 horizontal surface
7.4 vertical surface
7.5 double curvature
7.6 concave surface
7.7 convex surface
7.8 return surfaces
7.9 joggle details
7.10 nett edges
8 Produce a range of mouldings using one type of resin from:
8.1 bio resin
8.2 acrylic
8.3 polyester
8.4 vinyl ester
8.5 epoxy
8.6 phenolic
8.7 other resin to be specified
9 Produce a range of mouldings using techniques for one type of fibre from:
9.1 natural fibre
9.2 thermoplastic
9.3 glass
9.4 aramid
9.5 carbon
9.6 hybrid
9.7 other fibre to be specified
10 Produce a range of mouldings using techniques for two types of reinforcement from:
10.1 uni-directional
10.2 roving
10.3 chopped strand
10.4 continuous filament
10.5 tissues/veils
10.6 bonded fabrics
10.7 woven
10.8 braids
10.9 tapes
10.10 multi axis/stitched
10.11 other reinforcement to be specified
11 Produce a range of mouldings using techniques for one type of core material from:
11.1 solid timber
11.2 end grain balsa
11.3 coremat
11.4 rigid foam
11.5 expanding foam
11.6 skinned honeycomb
11.7 other material to be specified
12 Use two of the following methods/processes if using core materials:
12.1 core templates
12.2 pre-shaping core
12.3 core chamfers
12.4 core splicing
12.5 peel plies
12.6 bonding paste
12.7 edge filling
12.8 adhesive/resin films
12.9 single stage curing
12.10 multi stage curing
13 Produce a range of mouldings which comply with one of the following standards:
13.1 BS, ISO or BSEN standards and procedures
13.2 customer standards and requirements
13.3 organisational standards and procedures
13.4 recognised compliance agency/body standards