Basic principles of composite fabrication & damage repair
All EFC composite repair courses comply SAE-CACRC, FAA and EASA standards.
This composite course is a Training ‘level 1-2’ composite fabrication and composite repair course. It is the key to the world of advanced composites like glassfiber, carbon fiber and Aramid fiber and is our most “Basic” and most wanted composite course and is designed to meet the requirements of a wide range of participants, composite technicians from beginner to an intermediate composite technician out of the composite industry who want to have a better understanding of advanced composites.
“None Required for this "Basic course ”This composite fabrication and repair course is also an advised prerequisite for other EFC courses such as the TECH-010 Intermediate of Composite damage repair, TECH-020 Advanced Repair course and our Tooling and fabricating courses.
Please, if in doubt do contact usto assess your level of knowledge and skills prior to enrolling.
Participants must be able to, understand speak, read and write technical English!
Personnel of technical departments of aviation maintenance having no prior or some experience or training with Fiber-Reinforced Advanced Composites and wanting to gain a better understanding of advanced composite materials and processes such as Wet lay-up, laminate panels with Glas, Carbon and aramid fiber materials, apply vacuum trough different bagging techniques, fabrication and repair.
Personnel with some composite fabrication or repair experience are also welcome to participate in this basic course.
Number of participants
Minimum required 2 and maximum 14 per course*.
* Courses will be confirmed as running by EFC as soon as sufficient applications are received!
To provide participants with the theoretical knowledge and practical Hands-On skills necessary to carry out basic fabrication and repair.
At the end of the course the participants:
Must be able to work independently with minimum supervision on advanced composite materials
Must be attentive to details
Can work according to Safety regulations find material properties in Safety Data Sheets (MSDS) and recognize hazardous situations & materials and can handle it accordingly
Knows how to find material properties and is familiar and can with “Handling & Storage” of frozen glass and carbon fiber materials
Can work safely with carbon fiber pre-pregs like UNI Carbon UD tape material and is familiar with the effects of orientation and ‘Balance’ and ‘symmetry’ in a laminate
Knows how to work with dry fiberglass cloth and liquid Epoxy resin to impregnate wet in wet "Wet Lay-Up" (WLU)
Can apply fundamental vacuum bagging, bleeder & breather concepts and apply leak checks
Can taper sand various taper ratios as required by OEM on fiberglass parts
Fabricate Carbon fiber and fiberglass flat and single curved panels with Nomex® honeycomb core
Performs a basic ‘Wet Lay Up’ repair on a fiberglass part
Course content theory
Health and Safety (MSDS)
History of composites, recent developments and terminology
Handling & Storage of Frozen materials
Material Forms: glassfiber dry cloth and wet resins vs. pre-preg, weave styles
Fundamentals of Fabrication: dry cloth and pre-preg handling, ply orientation, layup procedures, vacuum bagging techniques
Introduction to advanced composite materials/structures
Resin, adhesive systems: thermosets vs. thermoplastics, mix ratios, viscosity, service temperature limits, cold storage requirements/shelf life limits, mix ratios pot life, etc.
Material Data Sheet (MDS) reading to determine Open time, Shelf life, and material Cure cycles
Composite awareness & reporting damage incidents
Minor Damage assessment, and reporting dents scratches and others
Sanding techniques, scarf angels, ratios and step repairs, ply cutting
Participants will be daily intensively, individually monitored and evaluated by the instructor while fabricating and repairing their individual parts!
SAEA-CACRC ARP Documents During the practical, the participant has access to all necessary SAE-International CACRC ARP’s (Aerospace Recommended Practices) documents used during this course
Calculate Epoxy Resin-Hardener mix ratios by the weighing fiberglass panel
el by wet lay-up using dry fiberglass warp directions and resin bleed out by using various bleeder breather schemes in layup taken out surplus resin.
Lean practices how to taper sand on existing hand-out 4 ply panel with various sanding grids
Cutting an existing (Room temp cured) fiberglass panel in half, taper sand by ratio and extend panel by wet lay-up repair and cure
Learn how thaw pre-preg material is taken out of the freezer and how to fill in a freezer storage form, and make kit-cuts out of a roll and seal.
Panel Lay up a Carbon fiber UD g pre-preg glass and Aramid fiber with Nomex® Honeycomb and other core materials.
Debulking of plies according to
pre-preg carbon using warp clock layups
Sandwich panels layup using
Perform Vacuum bagging with Non-autoclave bleeder/breather materials using various types of pleats, avoid bridging and perform leak using leak checking forms solve leaks
Damage removal, scarf preparation for repair using a Wet Lay-Up and pre-preg repair process.
Work with oven cures Ramp-up soak and cool down
Demonstration: "How to use Hot Bond repair consoles" and their equipment like heat blankets, thermocouple placement and mapping.
Work with an industrial oven or Hot bond Heat console during the practical repair
Assessment activities are built into our courses, to give feedback on the achievement, personal potential and kept a record in a personal logbook per student.
Multiple choice questions from each of the teachings Level 1-2
Successful completion is 75% correct answers
The examination will be closed book and can be conducted by a Part 147 approved Examiner upon request
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 for unlimited time (compliant with Reference EASA Commission Regulation (EU) No 1321/2014) and the GDPR rules
A certificate of accomplishment is handed out to each participant
Assessment activities are built into our courses, to give feedback on the achievement and personal potential and kept a record in their personal logbook.
The final outcome of the participant's Examination, assessment document and logbook per student will be digitally sent to your company responsible manager or HR department.
We also comply with the European AVG/GDPR rules as effective on May 25th, 2018 concerning storage of private information of participants who attended our courses.
For your company to benefit, this course can be held ‘On-Site’ at your facility under certain conditions. Click on this link to the Onsite information webpage!
Courses as noted on our course schedule page can be run on request to meet your required start and end date.
All listed course prices are Excl VAT. (Dutch VAT is 21%). EFC complies with Dutch tax laws. On request, companies can be sent an invoice instead of paying direct On-line with PayPal, IDEAL or credit card.