Lesson 1Documentation and process control: batch records, material lot tracking, inspection reports and corrective action loggingThis section defines documentation and process control tools like batch records, material lot tracking, traveller sheets, inspection reports, and corrective action logging for audits, traceability, and improvement.
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 preparing moulds for layup, including surface finishing, cleaning, release agent selection and application, and using a mould inspection checklist to spot damage or contamination before production.
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 accurate ply cutting, nesting to cut waste, part marking for traceability, tool selection, template use, orientation marking, and recording ply IDs for configuration control.
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, sequence, draping and splicing, fibre orientation control, bridging avoidance, and compaction for consistent fibre volume and minimal 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 designing and assembling vacuum bag stacks, including peel ply, breather, bleeder selection, sealant tape, vacuum port layout, and leak-testing for uniform pressure and resin control.
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 designing curing schedules for carbon fibre parts, including ramp rates, dwell times, post-cure strategies, and oven or heat blanket setup for consistent properties without 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 resin storage, mixing, and impregnation, including mix ratios, pot life, degassing, wet-out techniques, infusion flow control, and visual cues for proper saturation without voids.
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 integrating cores, mandrels, and inserts into layups, covering location methods, bonding surfaces, fastener boss design, sacrificial mandrel strategies, and fixturing for alignment.
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 non-destructive and destructive checks like vacuum leak tests, ultrasonic or tap testing, thickness and core checks, insert pull tests, and dimensional verification to meet design 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 prep, edge finishing, and surface protection against delamination or drift.
Safe demolding and part handlingTrim line marking and rough trimmingDrilling, reaming, and boss preparationEdge finishing and chamfer techniquesDust extraction and PPE requirements
