Apprenticeship training course

Composites technician (level 3)

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Information about Composites technician (level 3)

Composite technicians produce polymer matrix composite components or final products to a specification.

• Knowledge, skills and behaviours:
  View knowledge, skills and behaviours

  Knowledge

  • Composite industry awareness. Range of composite products. Manufacturing environments. Types of customers.
  • Composite technician’s role. Limits of responsibility. Escalation procedures.
  • Health and safety regulations and standards awareness. Control of Substances Hazardous to Health (COSHH). Display Screen Equipment. Electrical safety and compliance. Fire safety. Hand arm vibration (HAVS). Health and Safety at Work Act – responsibilities. Human factors, ergonomics. Legionella. Lifting Operations and Lifting Equipment Regulations (LOLER). Lone working. Manual handling. Noise regulation. Provision and Use of Work Equipment Regulations (PUWER). Slips trips and falls. The Reporting of Injuries, Diseases and Dangerous Occurrences Regulations (RIDDOR). Working at Height. Working in Confined Spaces.
  • Health and safety practice. Risk assessment and risk mitigation in composites process manufacturing environment. Personal protective equipment (PPE) requirements: selection, inspection, operation, wearing, and disposal.
  • Environmental and sustainability regulations and guidance. Environmental hazards that can arise from composite operations. Environmental management systems standard. Environmental Protection Act. Environmental signage and notices.
  • Principles of sustainability and circular economy. Energy efficiency and reuse of materials. Recycling procedures. Principles of control and management of emissions and waste.
  • Definition of a composite. Interaction between resin and fibre. Types of core. Benefits of adding core. Advantages and disadvantages of composites.
  • The characteristics of finished composite products and their various applications.
  • The difference between thermoset and thermoplastics: mechanical and thermal benefits, processing requirements, and re-cycling potential.
  • Types of reinforcement materials: aramid, carbon, glass, natural fibres, and thermoplastic fibres; processing, cost, performance, benefits, and limitations.
  • Types of matrix materials: bismaleimide, cyanate ester, epoxy, phenolic, polyester, vinylester, and bio-derived: processing, cost, performance, benefits, and limitations.
  • The manufacture of materials: chopped strand mat, non-crimp fabrics, pre-impregnated, preforms, unidirectional, and woven reinforcements. Different weave styles: plain, satin and twill; impact on drape and mechanical properties.
  • Composite process materials and consumables: peel plies, release agents, release films, sealant tapes, and vacuum bag; application and benefits of use.
  • Hand lay-up techniques: open moulding, spray lay-up, and pre-impregnated. Resin infusion, resin transfer moulding, and closed moulding using vacuum techniques.
  • Awareness of automated lay-up: automated fibre placement, automated tape layup, braiding, and filament winding.
  • Plant, equipment, machinery, and hand tools used within composites manufacture: application and operation.
  • The curing cycle. Glass transition temperature (Tg). The science of pressure and vacuum.
  • Principles of process control and instrument control methodology.
  • Awareness of application of digital systems to support manufacture: CAD (computer-aided design), CAM (computer-aided manufacturing), CMM (coordinate measuring machine), and additive manufacture.
  • Composite tooling and product design process awareness.
  • Composite mould tool manufacture methods, techniques, and considerations.
  • Composite mould tool preparation and operation.
  • Composite manufacture processes and principles: moulding, laminating, and curing.
  • Process risk in composite manufacture and mitigation. Defect types and causes.
  • Composite repair techniques: step, scarf, gel, resin injection, and riveting.
  • Standard operating procedures, drawings, and work instructions: what are they, why they are important.
  • Quality, cost, and delivery (QCD) standards and their importance in the workplace.
  • Quality assurance, testing and inspection methods.
  • Documentation requirements.
  • Awareness of audits and their purpose.
  • Problem solving: root cause analysis, 5-Whys.
  • Continuous improvement (CI) techniques: lean, 6-sigma, KAIZEN, and 5S.
  • Information technology. Management information systems, word processing, spreadsheet, email, virtual learning platforms, document sharing platforms. General data protection regulation (GDPR). Cyber security.
  • Verbal communication techniques. Composite industry terminology.
  • Written communication techniques.
  • Principles of team working. Equality, diversity and inclusion.
  • Planning, prioritising, and time management techniques.

  Skills

  • Review drawings, instructions, or information to understand task.
  • Plan work. Identify and organise resources.
  • Identify hazards and risks in the workplace.
  • Apply health and safety procedures in compliance with regulations and standards.
  • Apply environmental and sustainability procedures in compliance with regulations and standards.
  • Apply sustainability principles for example, in choice of materials, minimising waste.
  • Prepare and use mould tools.
  • Select and check hand tools, equipment and machinery including calibration record.
  • Use or operate hand tools, equipment, and machinery.
  • Store mould tools, hand tools, and equipment.
  • Select, check, and prepare materials for example, weigh resins, cut reinforcement.
  • Follow quality control processes during manufacture for example, check for contaminants, record batch numbers or expiry dates.
  • Apply laminate to mould for example, cut, add darts, corner definition, orientation, position, and order.
  • Complete preparation for and start curing process for example, select and apply consumables for example vacuum bag, infuse with resin, add heat or pressure.
  • Extract product from mould (break out).
  • Conduct final product quality assurance procedure. For example, conduct grading parameters checks (size, appearance, weight), and take samples for laboratory testing.
  • Identify issues for example, de-laminations, inclusions, surface defects, surface imperfections, and maintenance requirements.
  • Escalate issues outside limits of responsibility.
  • Segregate resources for reuse, recycling, and disposal.
  • Record or enter data - paper based or electronic. For example, process and production records, traceability records, and quality assurance records.
  • Interpret data for example, defect data and geometrical measurements. Use data to validate suggestions.
  • Investigate a problem to identify the underlying cause. Identify a solution to the problem.
  • Apply continuous improvement techniques. Devise suggestions for improvement. For example, improving the energy consumption or waste profile of processes and procedures to improve the sustainability or carbon footprint of a product, process, or task.
  • Apply team working principles.
  • Communicate with others verbally for example, colleagues and stakeholders.
  • Communicate in written form in the workplace for example, handover notes or emails, non-conformances, design change requests.
  • Use information technology for work tasks. Comply with GDPR and cyber security regulations and policies.
  • Plan how to meet personal development needs. Carry out and record planned and unplanned continued professional development (CPD) activities. Evaluate CPD against plans made.

  Behaviours

  • Prioritise health and safety.
  • Consider the environment and sustainability.
  • Demonstrate professional integrity.
  • Take responsibility for the quality of work.
  • Team-focus with commitment to inclusivity.
  • Respond and adapt to work demands or situations.
  • Committed to continued professional development.
• Apprenticeship category (sector): Engineering and manufacturing
• Qualification level: 3; Equal to A level
• Course duration: 36 months
• Maximum funding: £27,000 ; Maximum government funding for ; apprenticeship training and assessment costs.

View more information about Composites technician (level 3) from the Institute for Apprenticeships and Technical Education.