Lesson 1Documentation an process control: batch records, material lot trackin, inspection reports an corrective action logginDis part define documentation an process control tools, includin batch records, material lot trackin, traveler sheets, inspection reports, an corrective action loggin fi support audits, traceability, an continuous improvement inna shop.
Material certificates and lot trackingShop travelers and routing sheetsIn-process and final inspection formsNonconformance and defect loggingCorrective and preventive action recordsLesson 2Mold prep: surface finish, release agent pickin, mold cleanin, an mold inspection checklistDis part describe how fi prep molds fi layup, includin surface finishin, cleanin, release agent pickin an applyin, an use a mold inspection checklist fi spot damage, contamination, or wear before composite production start.
Mold surface finishing and repairsCleaning procedures and solventsSemi-permanent and wax release agentsRelease application frequency and checksMold inspection checklist itemsLesson 3Ply cuttin, part markin an nestin: tools, templates, an traceability practices fi each plyDis part detail how fi cut plies proper, nest patterns fi cut waste, an mark parts fi full traceability, includin tool pickin, template use, orientation markin, an recordin ply IDs fi keep configuration control an 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 an handlin: drapin techniques, fiber orientation control, bridgin avoidance an ply compaction methodsDis part cover layup plannin an doin it, includin ply books, layup sequence, drapin an splicin, fiber orientation control, bridgin avoidance, an compaction methods fi get consistent fiber volume fraction an minimize defects.
Reading and using ply booksDraping, darting, and splicing pliesMaintaining fiber orientation accuracyAvoiding bridging in corners and radiiHand and vacuum ply compaction stepsLesson 5Baggin an vacuum setup: sealant tapes, peel/bleeder materials, vacuum portin layout an leak-testin procedureDis part explain how fi design an build vacuum bag stacks, includin peel ply, breather, an bleeder pickin, sealant tape use, vacuum port layout, an leak-testin procedures fi get uniform pressure an resin control durin 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 6Curin schedule an temperature control: ramp rates, dwell times, post-cure options an oven/heat blanket setupDis part explain how fi design an run curin schedules fi carbon fiber parts, includin ramp rates, dwell times, post-cure strategies, an setup a ovens or heat blankets fi ensure consistent laminate properties an 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 handlin an impregnation: mix ratios, degassin, wettin techniques, infusion flow balancin an visual cues fi proper impregnationDis part cover correct resin storage, mixin, an impregnation practices, includin mix ratios, pot life, degassin, wet-out techniques, infusion flow control, an visual cues weh show proper fiber saturation widout too much 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 an insert integration: locatin metal inserts, bonded fastener bosses, an sacrificial mandrel strategiesDis part explain how fi integrate cores, mandrels, an inserts inna composite layups, coverin location methods, bondin surfaces, fastener boss design, sacrificial mandrel strategies, an fixturin fi keep alignment durin cure an demoldin.
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 an destructive quality checks: vacuum leak test, ultrasonic or tap testin fi delaminations, core/thickness checks, bonded insert pull test an dimensional verificationDis part introduce non-destructive an destructive quality checks, includin vacuum leak tests, ultrasonic or tap testin, thickness an core checks, insert pull tests, an dimensional verification fi confirm parts meet design an 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 10Demoldin, trimmmin an machin: safe trimmmin techniques, drill/boss preps an edge finishinDis part focus pon safe demoldin, trimmmin, an machin a cured parts, includin tool pickin, dust control, drill an boss prep, edge finishin, an protection a critical surfaces fi avoid delamination, fiber 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
