Producing 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 components. 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 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 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 faults, and ensuring 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 done and how this will be achieved
4. obtain and prepare the appropriate tools, equipment and materials
5. carry out the moulding 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 production documentation

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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 (PPE) that you need to use for both personal protection and, where appropriate, protection of others
4. the hazards associated with moulding acrylic materials, and with the tools and equipment used, and how to minimise them and reduce any risks in the workplace
5. the interpretation of drawings, standards, quality control procedures and specifications used for the moulding activity, and the 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 followed during the moulding operations
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. the problems that can occur with the moulding operations, and how these can be overcome
19. the recording documentation to be completed for the moulding activities undertaken
20. the extent of your own authority and to whom you should report if you have problems that you cannot resolve

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

   1. obtain and use the appropriate documentation (such as job instructions, drawings, quality control documentation, material data sheets)
   2. adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
   3. obtain the correct tools and equipment for the activity and ensure they are safe to use
   4. use the correct materials and consumables, as specified in the production documentation
   5. apply safe and appropriate acrylic moulding practices and procedures at all times
   6. keep the work area in a safe and suitable condition

2. Carry out one of the following 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. stress relieving
   3. sheet preparation      
   4. sheet forming
   5. trimming         
   6. de-moulding
   7. setting and controlling temperatures

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

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

5. Produce a range of mouldings which comply 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. specific material/moulding requirements

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2

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31 Mar 2019

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Current

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Original

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Semta

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SEMMME2-33

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Engineering, Engineering and Manufacturing Technologies, Engineering Technicians

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5221

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engineering; manufacturing; mechanical; producing; acrylic moulds; vacuum forming; deep drawn; positive pressure shaping; press relieving; shape clamping

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