| 1 | 1a. Produce Composite Mouldings using Wet Lay-up Techniques | 1.1 | Work safely at all times, complying with health and safety and other relevant regulations and guidelines |
| 1.2 | Carry out all of the following during the moulding activities: • use the correct issue of production documentation (instructions, drawings, job cards) • use relevant health and safety documentation (material data sheets, COSHH sheets) • use the correct tools and equipment for the activity and ensure they are safe to use • use the correct materials and consumables, as specified in the production documentation • apply safe and appropriate wet lay-up working practices and procedures at all times • keep the work area in a safe condition |
| 1.3 | Follow the correct component drawing or any other related specifications for the component to be produced |
| 1.4 | Determine what has to be done and how this will be achieved |
| 1.5 | Obtain and prepare the appropriate tools, equipment and materials |
| 1.6 | Prepare the moulds and materials for the production activities, to include all of the following: • cleaning of tooling and removal of resin build-ups • checking of tooling for surface defects • correctly applying sealants/release agents • dispensing and applying the correct measure and mix of resin/catalyst |
| 1.7 | Carry out the moulding or laying-up activities using the correct methods and techniques |
| 2 | 1b. Produce Composite Mouldings using Wet Lay-up Techniques (continued) | 2.1 | Produce a range of mouldings, using two of the following application techniques: • spray application of fibre/resin • application of a gel coat • brush application of fibre/resin • roller application of fibre/resin • removal of voids and air pockets • use of vacuum bagging • use of bleed plies |
| 2.2 | Produce a range of mouldings incorporating one of the following in the lay-up: • feathered joins • overlap joins • orientated plies • inserts • fixtures • butt joins |
| 2.3 | Produce a range of mouldings, incorporating two of the following shape features: • internal corner • external corner • double curvature • concave surface • convex surface • vertical surface |
| 2.4 | Produce a range of mouldings using all the following: • resin (such as polyester, epoxy, phenolic, vinyl ester) • fibre (such as glass, carbon, polyethylene, aramid) • reinforcement (such as braids, roving, tapes, chopped strand, continuous filament, woven) • core material (such as wood, coremat, structural foam, honeycomb) |
| 2.5 | Produce components to the required specification which comply with one or more of the following: • ISO 9000 quality assurance procedures • customer standards and requirements • company standards and procedures |
| 2.6 | Check that all the required operations have been completed to specification |
| 2.7 | Deal promptly and effectively with problems within their control and report those that cannot be solved |
| 3 | 2a. Know how to Produce Composite Mouldings using Wet Lay-up Techniques | 3.1 | Explain the health and safety precautions to be taken, and procedures used in the specific work area, when working with composite materials, consumables, tools and equipment |
| 3.2 | Describe the hazards associated with working with composite materials, consumables, tools and equipment, and how to minimise these in the work area |
| 3.3 | Describe the protective equipment that is needed for personal protection and, where required, the protection of others |
| 3.4 | Explain the application of COSHH regulations in relation to the storage, use and disposal of composite materials and consumables |
| 3.5 | Explain how to use and extract information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS or ISO standards in relation to work undertaken) |
| 3.6 | Explain how to interpret and use imperial and metric systems of measurement |
| 3.7 | Describe the quality procedures used in the workplace to ensure production control (in relation to currency, issue, meeting specification, etc) |
| 3.8 | Explain the conventions and terminology used for wet lay-up techniques (eg, resin and fibre weights/volumes, material orientation, material identification, material tailoring, mixing ratios, gel times, exotherm, bleed plies, etc) |
| 3.9 | Explain the various type of resin, fibres and reinforcement used, and their applications |
| 4 | 2b. Know how to Produce Composite Mouldings using Wet Lay-up Techniques (continued) | 4.1 | Explain how to visually identify both raw and finished composite materials |
| 4.2 | Explain the methods of preparation of the patterns, moulds and tooling (including the correct use of surface sealers and release agents) |
| 4.3 | Explain the mixing ratios for gel coats, resins and catalysts, and their associated working times |
| 4.4 | Describe the methods used in the application of the resin/fibre during the lay-up activity |
| 4.5 | Describe tools and equipment used in the lay-up activities, and explain their care, preparation and control procedures |
| 4.6 | Explain how to recognise faults that can occur during the lay-up process |
| 4.7 | Describe the procedures and methods used for removing mouldings from the production tooling |
| 4.8 | Explain how to identify defects in the composite moulding (such as de-lamination, voids, contaminants, etc) |
| 4.9 | Describe the care and safe handling of production tooling and composite mouldings throughout the production cycle |
| 4.10 | Explain the production controls used in the work area, and describe actions to be taken for unaccounted items |
| 4.11 | Describe the extent of their own authority and explain whom they should report to if they have problems that they cannot resolve |
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