Composite Tooling Fabrication Stage I

Course code:  TECH-170 (Stage I)

Course duration: 5 Day

Introduction:
This is our In-depth tooling course (Stage I) which is designed and meant for Personnel of technical departments who want learn more about tool design and fabrication techniques to achieve tool stability and long long life cycles
Al learned will be applied in the workshop to fabricate an excellent tooling mould.

Advised Pre Requisites
Our EFC Courses, TECH-001-(Stage I) is a prerequisite, Previous experience with composite materials and layup is required for this course, or an equivalent level. Please, if in doubt contact us to assess your equivalent level of training.

Participants
Personnel of technical departments, tool designer, tooling engineer, tool fabricator, composite repair technician and others who want to learn about tool design and achieve in-depth skills in Composite Tooling fabrication and will be able to design and build moulds using Low Temperature Moulding (LTM) composite pre-preg materials.

Number of participants:  Minimum 2, Maximum 12 per course*.
* Courses will be confirmed as running by EFC as soon as sufficient applications are received! 

Objectives
At the end of this course the participant:

  • Ha a better knowledge of composite tool design
  • Knows the pre-preg part tooling routes
  • Knows and has the skills to surface preparation of a master model
  • Can read and understand Tooling Ply-Lay-Up drawings and tool design tolerances
  • Is familiar with tool index and trim fixtures
  • Can apply Tool back-yup structure stiffeners, fences, return flanges, egg crate or omega stiffeners design
  • Knows how to use and work with Wax sheet offsets
  • Can apply vacuum bags for tooling
  • Will have advanced knowledge and skills to apply of Low Temperature Moulding (LTM) materials
  • Has the knowledge and skills to fabricate quick composite reinforced repair tooling 

Content Theory (level 2-3)

  • Pre-preg part tooling routes and family
  • Tool codes and designations
  • Tooling back-up structure fabricated by infusion
  • Tooling fabricated by infusion
  • Tool support structure and integrated stiffener design
  • Tool index features
  • Mould tool joggle lay-up
  • Attachment of wet Lay-up cleats
  • Inserting of permanent vacuum points and air transportation venting lines
  • Coefficient of Thermal Expansion (CTE) and spring back correction
  • Use of pre-cured tool inserts
  • Application of de-bulks
  • Application of tool leak prevention frames
  • Cure cycle temperatures versus Tool life cycle
  • One-0ff tooling en prototyping
  • Application of Quick Repair Tooling
  • Tool numbering and  Tooling logbook
  • Tool maintenance, and tooling for repair
  • Tooling vacuum bag systems
  • Tooling materials and low and high Temp cure cycles and out-life time
  • Tool exothermic reactions
  • Reusable vacuum bags for tooling
  • Tool surface pinholing
  • Laminate wrinkling and bridging
  • Application of tool sealers and release agents
  • Fault finding check list

Workshop (Level 3)
The participant will be able to:

  • Prepare a master model
  • Extend existing flanges of a part
  • Apply Fences for return flanges
  • Apply wax sheets and wax radii
  • Apply tool index features
  • Apply support structure Omega stiffeners and or egg crate design
  • Apply leak prevention frames
  • Apply glass or carbon LTM tooling material
  • Fabricate a tool trim fixture with foam core material and dry fibers wet lay-up
  • Be able to program, monitor ovens parameters during curing to prevent exothermic reactions.
  • Check tooling for leaks according the water infusion method and apply leak prevention methods

Examination

  • Multiple choice questions from each of the teachings Levels 2-3
  • Successful completion is 75% correct answers (The examination is closed book)
  • The practical mark will be the average of all marks gained from the practical exercises 
  • All grades will be recorded in the participant individual training records and kept on record at EFC a for unlimited time (compliant with Reference EASA Commission Regulation (EU) No 1321/2014)

On-Site' Training
This course is not meant for  'On-Site' training at your company. 

For information & requirements, contact our business & purchasing manager Rolf Hovener via e-mail at r.a.hover@efcomposites.com or Owner / Founder Bert Groenewoud via e-mail at info@efcomposites.com

Course Pricing
all listed course prices are Excl. VAT. Dutch VAT is 21% (comparable with VAT). EFC complies with Dutch tax laws. Companies on request can receive an invoice instead of paying on-line with PayPal, IDEAL or credit card.