Lesson 1Documentation and process control: batch records, material lot tracking, inspection reports and corrective action loggingThis part sets up record-keeping and control tools, like batch sheets, material batch tracking, check reports, and fix logs for audits, tracing, 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 preparation: surface finish, release agent selection, mould cleaning, and mould inspection checklistThis part describes prepping moulds for layup, covering finish, cleaning, release picks and use, and checklists to spot damage, dirt, or wear before starting composites.
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 accurate ply cutting, pattern fitting to save waste, and marking for full tracking, with tool picks, templates, angle marks, and ply IDs for 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 sequence and handling: draping techniques, fibre orientation control, bridging avoidance and ply compaction methodsThis part covers layup planning and doing, including layer guides, order, draping and joins, fibre angle control, gap dodge, and squeeze methods for steady fibre fill and fewer 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 vacuum bag stack design and build, with peel cloth, breather, bleeder picks, seal tape, port layout, and leak tests for even pressure and resin during 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 cure plans for carbon parts, covering ramp speeds, hold times, extra cures, and oven or blanket setups for steady properties without 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 storage, mixing, and soak practices, with ratios, pot life, air removal, wet-out ways, flow control, and sight checks for good fibre soak without air or dry bits.
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 fitting cores, mandrels, inserts into layups, with place methods, bond faces, boss design, throwaway mandrel ways, and holds for line during cure and removal.
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 introduces no-harm and harm checks, like vacuum leaks, sound or tap tests, thickness and core checks, insert pulls, and size verifies to confirm parts meet design and safety.
Vacuum bag leak testing methodsTap and ultrasonic testing for flawsCore bond and laminate thickness checksBonded insert pull and shear testsDimensional inspection and tolerancesLesson 10Demoulding, trimming and machining: safe trimming techniques, drill/boss preparations and edge finishingThis part focuses on safe removal, trimming, machining of cured parts, with tool picks, dust control, drill and boss prep, edge finish, and surface safety from splits, pulls, or shifts.
Safe demolding and part handlingTrim line marking and rough trimmingDrilling, reaming, and boss preparationEdge finishing and chamfer techniquesDust extraction and PPE requirements
