Lesson 1Documentation and process control: batch records, material lot tracking, inspection reports and corrective action loggingThis part sets record and control tools, like batch sheets, material batch track, traveler forms, check reports, fix logs for audits, tracking, and shop improvement.
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 checklistThis part describes prepping molds for layup, with finish, clean, release pick and put-on, and check list to spot damage, 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 plyThis part details accurate ply cutting, pattern fitting to save waste, part marks for tracking, tool pick, template use, direction marks, ply IDs for 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 methodsThis part covers layup plan and do, with ply books, order, drape and join, fiber direction hold, no-bridge, squeeze ways for steady fiber amount and less 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 procedureThis part explains bag stack design and build, peel ply, breather, bleeder pick, seal tape, vacuum spots, leak tests for even press and resin 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 part explains cure plans for carbon parts, ramp speeds, hold times, extra cure, oven or blanket setup for steady properties and no 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 impregnationThis part covers right resin store, mix, soak ways, ratios, pot life, air out, wet tech, flow control, sight signs for good fiber soak no extra voids or dry.
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 part explains adding cores, mandrels, inserts to layups, place ways, bond faces, boss design, throw-away mandrel plans, holds for line during cure and remove.
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 part brings no-harm and harm quality checks, vacuum leak, sound or tap tests, thickness core checks, insert pull, size verify to meet design and safety.
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 finishingThis part focuses safe remove, trim, machine cured parts, tool pick, dust hold, drill boss prep, edge finish, protect key faces from split, fiber pull, size shift.
Safe demolding and part handlingTrim line marking and rough trimmingDrilling, reaming, and boss preparationEdge finishing and chamfer techniquesDust extraction and PPE requirements
