Composite Training

Lesson 1 • Fiber Reinforcement Types

Surveys carbon, glass, aramid, and natural fibers by mechanical properties and cost. Connects fiber selection to structural performance requirements.

Lesson 2 • Composite Architecture and Lay-Up

Introduces ply orientation, stacking sequences, and laminate notation. Explains how architecture drives anisotropic mechanical behavior.

Lesson 3 • What Are Composite Materials

Defines composites as engineered combinations of two or more constituents. Establishes the conceptual baseline for all subsequent material selection and fabrication topics.

Lesson 4 • Matrix Systems Overview

Covers thermoset and thermoplastic matrices, including epoxy, polyester, and PEEK. Links matrix choice to processing method and end-use environment.

Lesson 1 • Ventilation and Exposure Controls

Covers engineering controls including local exhaust ventilation and enclosures. Connects control hierarchy to permissible exposure limits.

Lesson 2 • Safe Material Handling and Storage

Details storage conditions for prepregs, resins, and solvents to maintain material integrity and safety. Covers labeling, segregation, and shelf-life tracking.

Lesson 3 • Emergency Response Procedures

Prepares technicians to respond to spills, fires, and exposure incidents in composite shops. Builds confidence through scenario-based protocol review.

Lesson 4 • Personal Protective Equipment

Specifies PPE selection for each composite process stage. Reinforces correct donning, doffing, and inspection procedures.

Lesson 1 • Mold Surface Preparation

Covers sealing, priming, and polishing sequences to achieve defect-free mold surfaces. Directly impacts surface finish and demolding success.

Lesson 2 • Tooling Material Selection

Compares aluminum, steel, composite, and foam tooling by thermal expansion, cost, and production volume. Aligns tool material to process and part requirements.

Lesson 3 • Tooling Maintenance and Life Extension

Establishes inspection intervals, repair procedures, and storage practices to maximize mold service life. Reduces scrap caused by tooling degradation.

Lesson 4 • Release Agent Application

Explains wax, semi-permanent, and water-based release systems and their application protocols. Prevents part adhesion and mold damage during demolding.

Lesson 1 • Resin Mixing and Pot Life Management

Covers stoichiometric mixing ratios, mixing technique, and pot life monitoring. Errors here cause incomplete cure and structural defects.

Lesson 2 • Fabric Cutting and Kitting

Teaches pattern development, bias cutting, and kit preparation for complex geometries. Accurate kitting reduces waste and lay-up errors.

Lesson 3 • Demolding and Initial Inspection

Covers safe demolding sequences, part trimming, and visual quality checks. Connects fabrication quality to downstream inspection standards.

Lesson 4 • Ply Placement and Wet-Out

Demonstrates sequential ply placement, resin application, and roller consolidation. Proper wet-out eliminates dry spots and voids.

Lesson 1 • Vacuum Bag Assembly Components

Identifies peel ply, breather, bagging film, sealant tape, and fittings and explains each component's function. Correct assembly is prerequisite to achieving target vacuum levels.

Lesson 2 • Vacuum System Setup and Leak Testing

Covers pump selection, gauge calibration, and systematic leak detection procedures. Undetected leaks cause porosity and resin-rich zones.

Lesson 3 • Flow Front Monitoring and Control

Teaches visual and sensor-based flow front tracking and corrective actions for dry spots. Ensures complete wet-out before gel.

Lesson 4 • Post-Infusion Cure and Demolding

Details cure cycle management under vacuum, bag removal sequence, and part extraction. Maintains dimensional accuracy achieved during infusion.

Lesson 1 • Prepreg Cutting and Ply Kitting

Applies automated and manual cutting methods to prepreg plies with precise fiber angle control. Accurate kitting is critical for laminate balance and symmetry.

Lesson 2 • Lay-Up on Complex Geometry

Addresses darts, splices, and tack techniques for conforming prepreg to curved and compound surfaces. Minimizes bridging and wrinkles that cause structural defects.

Lesson 3 • Prepreg Material Handling

Covers cold storage, out-time tracking, and thawing procedures for prepreg rolls and kits. Improper handling degrades resin flow and adhesion.

Lesson 4 • Out-of-Autoclave Prepreg Processing

Covers oven-cure and press-cure alternatives for OOA prepreg systems. Expands process options while maintaining quality benchmarks.

Lesson 1 • Accept/Reject Criteria and Reporting

Applies engineering drawing limits and specification thresholds to NDI findings. Produces compliant inspection records and disposition documentation.

Lesson 2 • Ultrasonic Inspection Techniques

Introduces pulse-echo and through-transmission ultrasonic methods for internal defect mapping. Ultrasonic testing is the primary NDI method for composite structures.

Lesson 3 • Visual and Tap Testing Methods

Covers systematic visual inspection and coin/tap hammer techniques for near-surface defect detection. Establishes baseline NDI skills before instrument-based methods.

Lesson 4 • Thermographic and Other Advanced Methods

Surveys flash thermography, shearography, and X-ray for specialized defect detection scenarios. Expands the technician's NDI toolkit beyond ultrasonics.

Lesson 1 • Sandwich Structure Repair

Addresses core replacement, potting compound injection, and face sheet restoration for sandwich panels. Restores both compressive and shear load paths.

Lesson 2 • Surface and Cosmetic Repair Methods

Covers gel coat fill, surface ply replacement, and fairing compound application for non-structural damage. Restores aerodynamic and cosmetic surface quality.

Lesson 3 • Wet Lay-Up Structural Repair

Applies scarfed and stepped patch geometry to restore load-carrying capacity in solid laminates. Builds on wet lay-up skills from earlier fabrication training.

Lesson 4 • Prepreg and Bonded Repair Methods

Covers prepreg patch preparation, adhesive film bonding, and heat blanket cure for in-situ repairs. Achieves higher strength restoration than wet lay-up repairs.