Producing pattern, corebox or model components by FRP moulding

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This standard identifies the competencies you need to produce fibre-reinforced plastic (FRP) patterns, negatives, corebox and model components, in accordance with approved procedures. You will be required to use appropriate manufacturing drawings, instructions, specifications and quality documentation to produce the various types of component.

The size, shape and complexity of the parts to be produced will vary, and it is anticipated that some components will be produced from existing pattern or model equipment, and others from preformed structures or formers. The components to be produced may combine a range of techniques and shapes, and will have features that include flat laminates, box/tray sections, double curvatures, convex or concave profile, stiffened mouldings and inserts.

Your responsibilities will require you to comply with organisational policy and procedures for the moulding activities undertaken, and to report any problems with the moulding activities, materials or equipment that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum 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 FRP moulding procedures. You will understand the moulding techniques and procedures used, and their application, and will know about the tools, equipment, techniques, materials and consumables, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring that the components produced are 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. complete relevant data and documentation

9. deal promptly and effectively with problems within your control and report those that cannot be solved

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1. the specific safety practices and procedures that you need to observe when working with fibre reinforced plastics (such as any specific legislation, regulations/codes of practice for the activities, equipment, materials)
2. the health and safety requirements of the work area where you are carrying out the moulding 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 carrying out FRP moulding activities, and with the tools, materials and equipment used, and how they can be minimised
5. the procedure for the correct separation and safe disposal of waste materials
6. 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
7. the use of and conventions/terminology used in moulding/laying up (such as material tailoring, `B' staging, vacuum bagging, backing materials, peel piles, bleed felt, foaming adhesives, intensifiers, autoclave techniques, material wet lay-up, dry fibre drying procedures)
8. the types of component trimming/cutting methods available, and trimming methods on the tool
9. the methods of achieving consolidation at foam/honeycomb/discontinuous laying-up points
10. the reasons for part-cure procedures, and their effect
11. the material types and their merits (such as material life, their construction, types of weave, resins, bulk problems with liquid resins, thermoplastics, pre-impregnated materials, foam, honeycomb, discontinuous materials)
12. the function and application of the following materials: release agents, gel coats, fibre matting, liquid resins, catalysts, accelerators, hardeners and fillers
13. the different mixing methods (manual and mechanical) that can be used when preparing materials for use
14. how different materials can be used to provide: longer working times; rigid, strong and hard wearing surfaces; backing up mediums; short or long curing times
15. the procedures when temperature cure is used, and the need for thermocouples on temperature control
16. the procedures for remoulding, lost wax removal and first article inspection (such as test samples, non-destructive testing (NDT) requirements)
17. the quality control procedures that need to followed during the lay-up moulding operations
18. the procedures for ensuring you have the correct type of tools and equipment
19. the methods and techniques for lifting, handling and supporting the components/equipment/materials during the lay-up moulding activities
20. recognition of lay-up/moulding defects (such as misalignment, distortion, foreign object damage, contamination, surface defects)
21. the tools and equipment used in the lay-up moulding activities, and their calibration, care, preparation and control procedures
22. the problems that can occur with the lay-up/moulding operations, and how these can be overcome
23. the recording documentation that needs to be completed for the lay-up/moulding activities undertaken and, where appropriate, the importance of marking and identifying specific pieces of work in relation to the documentation
24. the extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

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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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29 Apr 2021

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Current

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Original

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Semta

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SEMPAT16

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Engineering, Engineering and Manufacturing Technologies, Functional Managers, Managers and Senior Officials

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3113

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engineering; woodworking; pattern making; model making; manufacture; patterns; corebox; model; components; FRP; vacuum bagging

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