| 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: • obtain and use the appropriate documentation (such as job instructions, drawings, material data sheets, specifications, planning and quality control documentation) • adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work • provide and maintain a safe working environment for the wet lay-up activities • check that all tools and equipment to be used are in a safe and usable condition • follow safe practice/approved wet lay-up moulding techniques at all times • return all tools and equipment to the correct location on completion of the wet lay-up activities • leave the work area in a safe and appropriate condition on completion of the activities |
| 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 | Carry out all of the following activities when preparing production tooling: • check that tooling is correct and complete • clean tooling and remove resin build-ups • check for surface defects • correctly apply sealers/release agents • clean and store tooling suitably after use |
| 1.7 | Carry out all of the following activities to prepare materials for production: • obtain correct materials for the activity • check that materials are fit for purpose and in life • cut materials to correct size and shape • check quantities of resins etc. are available • identify and protect materials in the work area • check correct measure and mix of resin/catalyst |
| 1.8 | Carry out the moulding or laying-up activities using the correct methods and techniques |
| 1.9 | Produce a range of mouldings using three 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 |
| 1.10 | Produce a range of mouldings incorporating two of the following in the lay-up: • feathered joins • overlap joins • orientated plies • inserts • fixtures • butt joins |
| 2 | 1b. Produce composite mouldings using wet lay-up techniques (continued) | 2.1 | Produce a range of mouldings incorporating three of the following shape features: • internal corner • external corner • double curvature • concave surface • convex surface • vertical surface |
| 2.2 | Produce a range of mouldings using techniques for one type of resin from: • polyester • vinyl ester • epoxy • phenolic |
| 2.3 | Produce a range of mouldings using techniques for one type of fibre from: • polyethylene • glass • aramid • carbon |
| 2.4 | Produce a range of mouldings using techniques for two types of reinforcement from: • roving • braids • tapes • chopped strand • continuous filament • woven |
| 2.5 | Produce a range of mouldings using techniques for one type of core material from: • wood • coremat • foam • honeycomb |
| 2.6 | Produce components to the required specification |
| 2.7 | Produce a range of mouldings which comply with one of the following standards: • BS, IS or BSEN standards and procedures • customer standards and requirements • company standards and procedures |
| 2.8 | Check that all the required operations have been completed to specification |
| 2.9 | 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 | Describe the health and safety precautions to be taken and procedures used when working with composite materials, consumables, tools and equipment in the specific work area |
| 3.2 | Describe the hazards associated with carrying out wet lay-up moulding techniques, and with the composite materials, consumables, tools and equipment used, and how to minimise these and reduce any risks |
| 3.3 | Describe the protective equipment that is needed for personal protection and, where required, the protection of others |
| 3.4 | Describe the application of COSHH regulations in relation to the storage, use and disposal of composite materials and consumables |
| 3.5 | Explain how to extract and use information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS, ISO or BSEN standards) in relation to work undertaken |
| 3.6 | Explain how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing |
| 3.7 | Describe the quality procedures used in the workplace to ensure production control (in relation to currency, issue, meeting specification) and the completion of such documents |
| 3.8 | Describe the conventions and terminology used for wet lay-up techniques (such as resin and fibre weights/volumes, material orientation, material identification, material tailoring, mixing ratios, gel times, exotherm, bleed plies) |
| 3.9 | Describe the different types of resins, fibres, reinforcement, and their merits |
| 3.10 | Describe the visual identification of both raw and finished composite materials |
| 3.11 | Describe the different types of production tooling used for producing composite mouldings |
| 3.12 | Describe the identification and rectification of defects in production tooling |
| 4 | 2b. Know how to produce composite mouldings using wet lay-up techniques (continued) | 4.1 | Describe the methods of preparation for patterns, moulds and tooling (including the correct use of surface sealers and release agents) |
| 4.2 | Describe the methods for handling and preparing the reinforcing fibres |
| 4.3 | Explain how to estimate the resin volume/weight required to wet-out the reinforcing fibres |
| 4.4 | Describe the mixing ratios for gel coats, resins and catalysts, and the associated working times |
| 4.5 | Describe the methods used in the application of the resin/fibre during the lay-up activity |
| 4.6 | Describe the tools and equipment used in the lay-up activities and their care, preparation and control procedures |
| 4.7 | Describe the problems that can occur during the lay-up process (including defects such as contamination, resin/fibre rich areas, and distortion) |
| 4.8 | Explain how defects can be overcome during the lay-up activity |
| 4.9 | Describe the procedures and methods used for removing mouldings from production tooling |
| 4.10 | Describe the identification of defects in the composite moulding (such as de-lamination, voids, contaminants) |
| 4.11 | Describe the care and safe handling of production tooling and composite mouldings throughout the production cycle |
| 4.12 | Describe the production controls used in the work area, and actions to be taken for unaccounted items |
| 4.13 | Explain how the composite moulding relates to its own quality documents and the production tooling used |
| 4.14 | Describe the extent of their own responsibility and to whom they should report if they have problems that they cannot resolve |
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