Lesson 1Documentation and process control: batch records, material lot tracking, inspection reports and corrective action loggingThis part sets paper and step watch tools, including batch notes, material lot track, travel sheets, check reports, and fix action logs to back checks, track, and steady better in the shop.
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 how to ready molds for layup, covering face finish, clean, release pick and put, and use of mold check list to find harm, dirt, or wear before composite work starts.
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 how to cut plies true, fit patterns to cut waste, and mark parts for full track, including tool pick, template use, direction mark, and note ply IDs for setup hold and fix past.
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, including ply books, layup order, drape and join, fiber direction watch, bridge stop, and press ways to get steady fiber volume and cut 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 how to design and build vacuum bag stacks, including peel cloth, breather, bleeder pick, seal tape use, vacuum door plan, and leak-check steps for even press and resin hold 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 part explains how to design and run cure plans for carbon parts, covering rise speeds, hold times, after-cure plans, and setup of ovens or heat cloths for steady laminate traits 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, and soak ways, including mix parts, pot life, air out, wet ways, pour flow hold, and sight signs for good fiber soak without too many 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 and insert integration: locating metal inserts, bonded fastener bosses, and sacrificial mandrel strategiesThis part explains how to join cores, sticks, and inserts into composite layups, covering place ways, join faces, fastener boss design, throw-away stick plans, and hold to keep line in cure and take-out.
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, including vacuum leak tests, sound or tap check, thickness and core checks, insert pull tests, and size check to make sure parts meet design and safety needs.
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 on safe take-out, cut, and machine of cured parts, including tool pick, dust hold, drill and boss ready, edge finish, and guard of key faces to stop split, fiber pull, or size shift.
Safe demolding and part handlingTrim line marking and rough trimmingDrilling, reaming, and boss preparationEdge finishing and chamfer techniquesDust extraction and PPE requirements
