Lesson 1Documentation and process control: batch records, material lot tracking, inspection reports and corrective action loggingThis section defines documentation and process control tools, including batch records, material lot tracking, traveller sheets, inspection reports, and corrective action logging to support audits, traceability, and continuous improvement in the shop.
Material certificates and lot trackingShop travelers and routing sheetsIn-process and final inspection formsNonconformance and defect loggingCorrective and preventive action recordsLesson 2Mould preparation: surface finish, release agent selection, mould cleaning, and mould inspection checklistThis section describes how to prepare moulds for layup, including surface finishing, cleaning, release agent selection and application, and use of a mould inspection checklist to detect damage, contamination, or wear before composite production begins.
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 plyThis section details how to cut plies accurately, nest patterns to reduce waste, and mark parts for full traceability, including tool selection, template use, orientation marking, and recording ply IDs to maintain configuration control and repair 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, fibre orientation control, bridging avoidance and ply compaction methodsThis section covers layup planning and execution, including ply books, layup sequence, draping and splicing, fibre orientation control, bridging avoidance, and compaction methods to achieve consistent fibre volume fraction and minimise defects.
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 procedureThis section explains how to design and assemble vacuum bag stacks, including peel ply, breather, and bleeder selection, sealant tape use, vacuum port layout, and leak-testing procedures to achieve uniform pressure and resin control during 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 setupThis section explains how to design and run curing schedules for carbon fibre parts, including ramp rates, dwell times, post-cure strategies, and setup of ovens or heat blankets to ensure consistent laminate properties and avoid thermal defects.
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 impregnationThis section covers correct resin storage, mixing, and impregnation practices, including mix ratios, pot life, degassing, wet-out techniques, infusion flow control, and visual cues that indicate proper fibre saturation without excessive voids or dry spots.
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 strategiesThis section explains how to integrate cores, mandrels, and inserts into composite layups, covering location methods, bonding surfaces, fastener boss design, sacrificial mandrel strategies, and fixturing to maintain alignment during cure and demoulding.
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 verificationThis section introduces both non-destructive and destructive quality checks, including vacuum leak tests, ultrasonic or tap testing, thickness and core checks, insert pull tests, and dimensional verification to confirm that parts meet design and safety requirements.
Vacuum bag leak testing methodsTap and ultrasonic testing for flawsCore bond and laminate thickness checksBonded insert pull and shear testsDimensional inspection and tolerancesLesson 10Demoulding, trimming and machining: safe trimming techniques, drill/boss preparations and edge finishingThis section focuses on safe demoulding, trimming, and machining of cured parts, including tool selection, dust control, drill and boss preparation, edge finishing, and protection of critical surfaces to avoid delamination, fibre pull-out, or dimensional drift.
Safe demolding and part handlingTrim line marking and rough trimmingDrilling, reaming, and boss preparationEdge finishing and chamfer techniquesDust extraction and PPE requirements
