Composite Tooling Fabrication (Stage I)
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
All theory will be applied in the workshop to fabricate an excellent tooling mold.
Day(-s): 5 / Tech code: TECH-170
Our EFC Courses, TECH-001-(Stage I) is a prerequisite,
3 to 5-year previous experience with advanced composite materials and layup is advised for this course or an equivalent level.
If you are in doubt, about your level please do contact us to evaluate your equivalent level of training.
Personnel of technical departments, tool designer, tooling engineer, tool fabricator, composite repair technician and others who want to learn about tool design and building moulds to achieve in-depth skills in Composite Tooling fabrication using Low-Temperature Moulding (LTM) composite pre-preg materials.
Minimum required 2 and maximum 12 per course*.
* Courses will be confirmed as running by EFC as soon as sufficient applications are received!
At the end of the course the participant:
- Has a better knowledge of composite tool design and fabrication
- Knows the pre-preg part tooling routes to follow and can interpret CTE rules
- Knows and has the skills to apply 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 incorporate Leak frames
- Can fabricate and apply Tool backup 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 with pleats
- Will have advanced knowledge and skills to apply to Low-Temperature Moulding (LTM) Prepreg materials
- Health and Safety (MSDS)
- Pre-preg part tooling routes and family
- Tool codes/acronyms and designations
- Tool making from existing parts
- Tooling backup structure 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
- The coefficient of Thermal Expansion (CTE)
- Tool spring back correction and adjustable spring back correction
- Use of pre-cured tool inserts
- Application of de-bulks
- Application of tool leak prevention frames in edges/flanges
- Cure cycle temperatures versus Tool life cycle
- One-0ff tooling and prototyping
- Application of Quick Repair Tooling
- 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 pinhole filling
- Laminate wrinkling and bridging
- Application of tool sealers and release agents
- Tool Fault finding checklist
- Tool dry run finding hot and cold zones and TC placement
- Tool numbering and Tooling logbook information
- Tool maintenance, and tooling for repair
The participant will be able to:
- Surface Preparation of a master model
- Extend existing flanges of a model
- Apply Fences for return flanges
- Apply wax sheets and wax radii
- Keep a record of tooling prepreg Out-time sheets and layup travelers
- Apply tool index features
- Apply support structure Omega-shaped stiffeners and or egg crate design
- Apply leak prevention frames
- Apply glass fiber strands in each ply
- Fabricate fiberglass or carbon LTM tooling material
- Apply debulks
- Apply vacuum material without bridging of applied vacuum materials
- Apply vacuum materials for Non-autoclave cure and pleats for vacuum ports
- Fabricate a tool trim fixture with foam core material and dry fibers by wet lay-up
- Be able to program, monitor ovens parameters during curing to prevent exothermic reactions.
- Perform a heat serve before curing the actual cure
- After curing the tool perform leak Check by using the water infusion method and apply leak prevention methods when necessary to infuse resin.
- Making drill and trim fixtures
- 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.
This course can also be held at our facility in Leipzig Germany at the facilities of our partner HEICO. If you have a need for this, please contact our purchasing manager Rolf Hovener via his page.
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.
Payment is securely arranged via Mollie.nl . More information can be found on the website of Mollie.