Lesson 1Documentation and process control: batch records, material lot tracking, inspection reports and corrective action loggingThis section defines docs and controls like batch records, lot tracking, travellers, reports, corrective logs for audits, traceability, and shop improvements.
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 section describes prepping moulds for layup, surface finishing, cleaning, release agents, inspection checklists to spot damage or dirt 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 section details accurate ply cutting, nesting to save material, marking for traceability with tools, templates, orientation, recording 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, fibre orientation control, bridging avoidance and ply compaction methodsThis section covers layup planning/execution, ply books, sequence, draping/splicing, fibre control, bridging prevention, compaction for consistent volume and few 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 section explains vacuum bag stacks, peel ply, breather/bleeder, sealant tape, port layout, leak tests for uniform 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 section explains curing schedules for carbon parts, ramps, dwells, post-cures, oven/blanket setup for consistent properties without thermal issues.
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 section covers resin storage, mixing, impregnation, ratios, pot life, degassing, wet-out, flow control, visual signs for good saturation without voids/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 section explains integrating cores, mandrels, inserts, location, bonding, boss design, sacrificial strategies, fixturing for alignment 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 section introduces non-destructive/destructive checks like leak tests, ultrasonic/tap, thickness/core, pull tests, dimensions to confirm design/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 section focuses on safe demoulding, trimming, machining cured parts, tools, dust control, drilling, edge finishing, protecting surfaces from damage.
Safe demolding and part handlingTrim line marking and rough trimmingDrilling, reaming, and boss preparationEdge finishing and chamfer techniquesDust extraction and PPE requirements
