Lesson 1Documentation and process control: batch records, material lot tracking, inspection reports and corrective action loggingDis part go define documentation and process control tools, including batch records, material lot tracking, traveler sheets, inspection reports, and corrective action logging to support audits, traceability, 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 checklistDis part go describe how to prepare molds for layup, including surface finishing, cleaning, release agent selection and application, and use of mold inspection checklist to detect damage, contamination, or wear 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 plyDis part go detail how to cut plies accurately, nest patterns to reduce waste, and mark parts for full traceability, including tool selection, template use, orientation marking, and recording ply IDs for 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, fiber orientation control, bridging avoidance and ply compaction methodsDis part go cover layup planning and execution, including ply books, layup sequence, draping and splicing, fiber orientation control, bridging avoidance, and compaction methods to achieve consistent volume and minimize 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 procedureDis part go explain how to design and assemble vacuum bag stacks, including peel ply, breather, and bleeder selection, sealant tape use, vacuum port layout, and leak-testing to achieve 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 setupDis part go explain how to design and run curing schedules for carbon fiber parts, including ramp rates, dwell times, post-cure strategies, and setup of ovens or heat blankets to ensure consistent properties.
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 impregnationDis part go cover correct resin storage, mixing, and impregnation practices, including mix ratios, pot life, degassing, wet-out techniques, infusion flow control, and visual cues for proper fiber saturation.
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 strategiesDis part go explain how to integrate cores, mandrels, and inserts into composite 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 verificationDis part go introduce non-destructive and destructive quality checks, including vacuum leak tests, ultrasonic or tap testing, thickness and core checks, insert pull tests, and dimensional verification for 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 10Demolding, trimming and machining: safe trimming techniques, drill/boss preparations and edge finishingDis part go focus on safe demolding, trimming, and machining of cured parts, including tool selection, dust control, drill and boss preparation, edge finishing, and protection of surfaces to avoid damage.
Safe demolding and part handlingTrim line marking and rough trimmingDrilling, reaming, and boss preparationEdge finishing and chamfer techniquesDust extraction and PPE requirements
