Lesson 1Documentation and process control: batch records, material lot tracking, inspection reports and corrective action loggingSet up records and controls like batch sheets, material batch follows, check reports, fix logs for audits, tracking, and steady shop improvements.
Material certificates and lot trackingShop travelers and routing sheetsIn-process and final inspection formsNonconformance and defect loggingCorrective and preventive action recordsLesson 2Mold preparation: surface finish, release agent selection, mold cleaning, and mold inspection checklistPrep molds for layup with finish work, cleaning, release picks and use, checklists to spot harm, dirt, wear before starting composites.
Mold surface finishing and repairsCleaning procedures and solventsSemi-permanent and wax release agentsRelease application frequency and checksMold inspection checklist itemsLesson 3Ply cutting, part marking and nesting: tools, templates, and traceability practices for each plyCut layers true, nest to save cloth, mark for tracking with tools, patterns, angle notes, ID records for build control and fix history.
Cutting tools and maintenance routinesTemplates, CNC cutting, and nestingFiber orientation and grain direction marksPly ID, part ID, and revision markingTraceability logs for each cut plyLesson 4Layup sequence and handling: draping techniques, fiber orientation control, bridging avoidance and ply compaction methodsPlan and do layups with layer guides, order, shaping, joins, angle holds, bridge stops, squeeze ways for steady fiber fill and few faults.
Reading and using ply booksDraping, darting, and splicing pliesMaintaining fiber orientation accuracyAvoiding bridging in corners and radiiHand and vacuum ply compaction stepsLesson 5Bagging and vacuum setup: sealant tapes, peel/bleeder materials, vacuum porting layout and leak-testing procedureBuild vacuum bags with peel, breather, bleeder picks, seal tapes, port plans, leak tests for even press and resin flow in cure.
Peel ply, breather, and bleeder selectionBag film choice and pleat placementSealant tape application best practicesVacuum port layout and hose routingStatic and dynamic leak test methodsLesson 6Curing schedule and temperature control: ramp rates, dwell times, post-cure options and oven/heat blanket setupDesign cure plans with heat rises, holds, extra cures, oven or blanket setups for uniform part traits without heat faults.
Selecting ramp and cool-down ratesSetting dwell times for full curePost-cure options for higher TgOven and heat blanket calibrationThermocouple placement and loggingLesson 7Resin handling and impregnation: mix ratios, degassing, wetting techniques, infusion flow balancing and visual cues for proper impregnationRight resin store, mix, soak ways with ratios, life, air removal, wet methods, flow balance, sight signs for full fiber fill sans voids or dries.
Resin storage, thawing, and conditioningAccurate mix ratios and pot life controlVacuum and mechanical resin degassingHand layup wetting and roll-out methodsInfusion flow fronts and visual indicatorsLesson 8Core, mandrel and insert integration: locating metal inserts, bonded fastener bosses, and sacrificial mandrel strategiesFit cores, mandrels, inserts in layups with place methods, bond faces, boss builds, dissolving cores, holds for align in cure and pull-out.
Core selection and edge close-out prepLocating and fixturing metal insertsBonded fastener boss design detailsRemovable and sacrificial mandrel optionsAdhesive selection for core and insertsLesson 9Non-destructive and destructive quality checks: vacuum leak test, ultrasonic or tap testing for delaminations, core/thickness checks, bonded insert pull test and dimensional verificationNon-harm and harm checks like vacuum leaks, sound or tap for splits, depth/core, pull tests, size confirms for design and safe standards.
Vacuum bag leak testing methodsTap and ultrasonic testing for flawsCore bond and laminate thickness checksBonded insert pull and shear testsDimensional inspection and tolerancesLesson 10Demolding, trimming and machining: safe trimming techniques, drill/boss preparations and edge finishingSafe pull-out, cut, machine cured parts with tool picks, dust hold, drill prep, edge work, guard key faces from splits, pulls, shifts.
Safe demolding and part handlingTrim line marking and rough trimmingDrilling, reaming, and boss preparationEdge finishing and chamfer techniquesDust extraction and PPE requirements
