Producing pattern, corebox or model components using cast resin techniques

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This standard identifies the competencies you need to cast resin pattern parts, coreboxes, corebox parts and model components, in accordance with approved procedures. You will be required to use appropriate manufacturing drawings, instructions, specifications and documentation, together with other 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 originals and duplicates will be used in the process. Individual sections of patterns, coreboxes and models will be cast from existing equipment when alterations, modifications or repairs are required.

Your responsibilities will require you to comply with organisational policy and procedures for the resin casting activities undertaken, and to report any problems with the casting activities, materials or equipment used 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 resin casting procedures. You will understand the resin casting requirements and procedures, and their application, and will know about the tools, techniques, materials and consumables used, 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 casting 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 cast resin materials and procedures (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 they place on you
3. the protective equipment (PPE) that you need to use for personal protection and, where appropriate, the protection of others
4. the hazards associated with carrying out resin casting activities (tools, materials and equipment), 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 casting activity, and the currency/issue checks of the documents you are working with
7. the use of, and conventions/terminology used in, resin casting
8. the procedures for ensuring that you have the correct tools and equipment for the casting activities, and how to check that they are in good order and fit for purpose

9. the different methods used to produce cast resin components for pattern or model making

10. the types of resin and other materials that are used in the casting process, and why different amounts of materials are used in the resin mixes

11. the function and application of the following materials: release agents, liquid resins, catalysts, accelerators, pigments, wax, stoppers, fillers, inserts
12. the different mixing methods that can be used when preparing materials for use (both manual and mechanical)
13. the correct sequence and technique of mixing the various materials together, and the effects on the cast resins of using incorrect sequences and volumes
14. the importance of keeping the masters clean and free from damage; practicing good housekeeping of mixing tools, containers and equipment; maintaining a clean, unobstructed and well ventilated working area
15. methods of removing the completed casting from the moulds without causing damage to the casting or the mould
16. methods of trimming and dressing the finished casting, and the tools and techniques that are used
17. the quality control procedures to be followed during the casting operations
18. recognition of casting defects (contamination and surface defects), their cause, effect and prevention
19. the problems that can occur with the resin casting operations, and how these can be overcome
20. the recording documentation that needs to be completed for the resin casting activities undertaken
21. marking and identifying specific pieces of work in relation to the documentation, where appropriate
22. 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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SEMPAT19

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

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5221

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engineering; woodworking; pattern making; model making; manufacture; cast resin; patterns; corebox; model components; resin casting equipment; techniques

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