Producing pattern, corebox or model components using flexible composite materials

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This standard identifies the competencies you need to produce flexible composite moulds for model components, using hand tools and equipment, in accordance with approved procedures. You will be required to select the appropriate tools and equipment to use, based on the type, size and material of the mould to be produced. The size, shape and complexity of the moulds to be produced will vary, so you must set out the mould masters to ensure the number, quality and accuracy of the models produced per mould is achieved.

You will also be expected to set up the machine moulding parameters, such as mould pressures, mould temperatures, curing and setting times, safely and correctly. Extracting the finished moulds, cutting runner and air release systems, and inspecting the mould cavities for defects, will also form part of your role.

Your responsibilities will require you to comply with organisational policy and procedures for the 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 flexible composite moulding techniques and procedures. You will understand the moulding techniques and procedures used, and their application, and will know about the relevant equipment, tools and materials, 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 activities. 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 relevant specifications for the mould to be produced
3. obtain the appropriate tools and equipment for the moulding operations and check they are in a safe and usable condition
4. shape the mould materials using appropriate methods and techniques
5. check that all the required mould shaping operations have been completed to the required specification

6. produce the required mould

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

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1. the specific safety precautions to be taken whilst carrying out the flexible composite moulding operations (such as any specific legislation, regulations or codes of practice relating to the activities, equipment or materials)
2. the health and safety requirements of the work area in which you are carrying out the moulding activities, and the responsibility these requirements place on you
3. the hazards associated with producing flexible composite moulds, and how they can be minimised
4. the personal protective equipment and protective clothing (PPE) to be worn during the moulding and forming activities
5. how to obtain the necessary job instructions, drawings and related specifications, and how to interpret their information correctly
6. the range of hand tools and associated equipment that is used to cut, shape and form materials used in flexible composite moulds
7. how to check that the tools and equipment to be used are in a safe and usable condition
8. the importance of ensuring that all tools and equipment are used in the correct manner, only for their intended purpose, and within their permitted operating range
9. how to identify the materials to be used, material identification systems, and any codes that are used
10. the various techniques used to form and shape rubber and silicone materials
11. how to prepare the masters and arrange them around the mould (marking out positions for the masters, positioning them around the mould, inserting mould location dowels, applying mould release agents)
12. how to set up flexible composite moulding machines for the correct pressures, temperature, curing and setting times
13. the effects on the completed moulds of using incorrect pressure or temperature during the curing process
14. how to remove moulds safely from the machine, and extract the masters, without causing damage to the mould cavities
15. how to finish the moulds by cutting runner and air release systems, and how to inspect them for defects
16. the identification of defects in the models which can be directly related to incorrect running, siting of the masters and incorrect air release systems
17. why it is important to keep the model masters clean and free from damage, to practice good housekeeping of tools and equipment, and to maintain a clean and unobstructed working area
18. the quality control procedures to be followed, and how to conduct any necessary checks to ensure the accuracy and quality of the moulds produced
19. the problems that can occur with the moulding and forming operations, and how these can be overcome
20. 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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SEMPAT29

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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; produce; components; flexible composite materials; flexible models; rubber moulds; silicon moulds; moulding techniques

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