Lesson 1Papers and process watch: batch notes, material lot track, check reports and fix action logThis part sets paper and process watch tools, including batch notes, material lot track, travel sheets, check reports, and fix action log to help checks, track, and steady better 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 ready: face finish, release pick, mould clean, and mould check listThis part describes how to ready moulds for layup, including face finish, clean, release pick and put, and use of mould check list to find harm, dirt, or wear before fibre making starts.
Mold surface finishing and repairsCleaning procedures and solventsSemi-permanent and wax release agentsRelease application frequency and checksMold inspection checklist itemsLesson 3Ply cut, part mark and fitting: tools, shapes, and track ways for each plyThis part details how to cut plies true, fit shapes to cut waste, and mark parts for full track, including tool pick, shape use, direction mark, and note ply IDs to keep build watch and fix story.
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 order and handle: lay ways, fibre direction watch, bridge stop and ply press waysThis part covers layup plan and do, including ply books, layup order, lay and join, fibre direction watch, bridge stop, and press ways to get steady fibre volume part and cut 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 set: seal tapes, peel/bleed materials, vacuum door plan and leak-check stepThis part explains how to design and build vacuum bag stacks, including peel ply, breather, and bleeder pick, seal tape use, vacuum door plan, and leak-check steps to get even press and resin watch 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 6Cure plan and heat watch: rise speeds, hold times, after-cure choices and oven/heat cloth setThis part explains how to design and run cure plans for carbon fibre parts, including rise speeds, hold times, after-cure plans, and set of ovens or heat cloths to make sure steady layer qualities and stop 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 handle and soak: mix parts, air out, wet ways, pour flow balance and sight signs for good soakThis part covers right resin store, mix, and soak ways, including mix parts, pot life, air out, wet-out ways, pour flow watch, and sight signs that show good fibre full without too much air or dry places.
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, stick and fit join: place metal fits, stuck fastener bosses, and give-up stick plansThis part explains how to join cores, sticks, and fits into fibre layups, covering place ways, stuck faces, fastener boss design, give-up stick plans, and hold to keep line during cure and take-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 9No-harm and harm quality checks: vacuum leak test, sound or tap check for splits, core/thick checks, stuck fit pull test and size checkThis part brings no-harm and harm quality checks, including vacuum leak tests, sound or tap check, thick and core checks, fit pull tests, and size check to show parts meet design and safety needs.
Vacuum bag leak testing methodsTap and ultrasonic testing for flawsCore bond and laminate thickness checksBonded insert pull and shear testsDimensional inspection and tolerancesLesson 10Take-out, cut and machine: safe cut ways, drill/boss ready and edge finishThis part focuses on safe take-out, cut, and machine of cured parts, including tool pick, dust watch, drill and boss ready, edge finish, and guard of key faces to stop split, fibre pull, or size shift.
Safe demolding and part handlingTrim line marking and rough trimmingDrilling, reaming, and boss preparationEdge finishing and chamfer techniquesDust extraction and PPE requirements
