Lesson 1Documentation and process control: batch records, material lot tracking, inspection reports and corrective action loggingThis sets docs and controls like batch sheets, lot tracking, travellers, reports, fix logs for audits, tracking, shop 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 describes mould prep for layup, finish, clean, release pick/apply, checklist for damage, dirt, wear before starting.
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 details accurate ply cutting, nesting to save, marking for track, tools, templates, orientation, IDs for control, 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 covers layup plans, books, sequence, drape/splice, fibre control, bridge dodge, compact for even fibre, low 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 explains bag stacks, peel/breather/bleeder, seal tape, ports, leak tests for even pressure, resin control 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 6Curing schedule and temperature control: ramp rates, dwell times, post-cure options and oven/heat blanket setupThis designs cure plans for carbon parts, ramps, holds, post-cures, oven/blanket setup for even properties, 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 covers resin store, mix, soak practices, ratios, life, degas, wet-out, flow control, signs of good soak sans voids/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 integrates cores/mandrels/inserts in layups, location, bond prep, boss design, soluble mandrels, fixtures for align in cure/demould.
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 intros non/dest checks: leak tests, ultra/tap for layers, thick/core, pull tests, size checks for design/safety meet.
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 focuses safe demould, trim, machine cured parts, tools, dust control, drill/boss prep, edge finish, protect sans delam/pull/drift.
Safe demolding and part handlingTrim line marking and rough trimmingDrilling, reaming, and boss preparationEdge finishing and chamfer techniquesDust extraction and PPE requirements
