Lesson 1Records and step control: batch sheets, material batch tracking, check reports and fix logsThis part sets record and step control tools, like batch sheets, material batch tracking, travel sheets, check reports, and fix logs to back checks, tracking, and steady shop improvement.
Material certificates and lot trackingShop travelers and routing sheetsIn-process and final inspection formsNonconformance and defect loggingCorrective and preventive action recordsLesson 2Mould prep: surface finish, release pick, mould clean, and mould check listThis part describes how to prep moulds for layup, covering surface finish, clean, release pick and put-on, and use of a mould check list to spot 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 3Layer cutting, part marking and fitting: tools, patterns, and tracking steps for each layerThis part details how to cut layers true, fit patterns to cut waste, and mark parts for full tracking, covering tool pick, pattern use, direction marks, and recording layer IDs for setup control and fix 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 order and handling: drape ways, fibre direction watch, bridge stop and layer press methodsThis part covers layup planning and doing, including layer books, layup order, drape and join, fibre direction watch, bridge stop, and press methods to get steady fibre 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: seal tapes, peel/bleeder stuff, vacuum port plan and leak-check stepsThis part explains how to design and build vacuum bag stacks, covering peel ply, breather, bleeder pick, seal tape use, vacuum port plan, and leak-check steps for even pressure and 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 6Cure plan and heat control: ramp speeds, hold times, extra-cure choices and oven/heat blanket setupThis part explains how to plan and run cure schedules for carbon fibre parts, covering ramp speeds, hold times, extra-cure plans, and setup of ovens or heat blankets for steady build qualities 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 soak: mix ratios, air remove, wet ways, infusion flow balance and sight signs for good soakThis part covers right resin store, mix, and soak steps, including mix ratios, pot life, air remove, wet-out ways, infusion flow watch, and sight signs for good fibre soak without too much air 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 fit join: placing metal fits, glued fastener bosses, and throw-away mandrel plansThis part explains how to join cores, mandrels, and fits into composite layups, covering place ways, glue faces, fastener boss design, throw-away mandrel plans, and holds to keep line-up in cure and remove.
Core selection and edge close-out prepLocating and fixturing metal insertsBonded fastener boss design detailsRemovable and sacrificial mandrel optionsAdhesive selection for core and insertsLesson 9No-harm and harm quality checks: vacuum leak test, sound or tap check for splits, core/thickness checks, glued fit pull test and size checkThis part brings no-harm and harm quality checks, like vacuum leak tests, sound or tap checks, thickness and core checks, fit pull tests, and size checks to confirm 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 10Mould remove, trim and machine: safe trim ways, drill/boss prep and edge finishThis part focuses on safe mould remove, trim, and machine of cured parts, covering tool pick, dust watch, drill and boss prep, edge finish, and safety of key faces to skip splits, fibre 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
