Wet Lay-up and Pre-Preg

Introduction to Composites, Wet Lay-up and Pre-Pregs

Course Code: 001
Duration: 5 Days
Course Fee: £1086 +VAT
Course structure: 30% theory, 70% practical

This course is aimed at anyone who requires a sound understanding of the terms, concepts and practices involved in producing composite parts and to gain a practical understanding of wet layup and pre-preg manufacturing techniques along with the health and safety requirements associated with them. The course is suitable for technicians, designers, engineers, managers and sales staff.

This course introduces the concepts, properties, structures and uses of advance and composite materials now being used across a number of different industries. This is combined with practical sessions which show the different manufacturing approach for wet layup and pre-preg layup at room and elevated temperatures; delegates produce simple forms with and without cellular thickening to aid their understanding of the different techniques. Safe handling and the risks involved in handling the materials involved in producing composites and damage prevention for completed parts along with the specific health and safety requirements needed are the backbone of this course.

The course will cover:

  • Health, safety and handling
  • Composite terminology, materials structure, properties and performance characteristics
  • Examining fibres, fabrics and drape.
  • Resin types, properties storage and disposal and rules of mixture
  • Materials life, cure methods – cure, secondary cure and bonding Tooling requirements and bagging Manufacture methods gel coat application
  • Laminating
  • Component surface finish and treatments effects
  • Material selection parameters
  • Material and tool preparation
  • Wet layup techniques, with and without vacuum bagging
  • Vacuum bagging options
  • Curing methods, temperature and pressure control

8th – 12th January 2024
15th – 19th July 2024
4th – 8th November 2024

Pre-Preg Laminating Stage 1

Course Code: 011
Duration: 5 Days
Course Fees: £1086 +VAT
Course structure: 30% theory, 70% practical

This foundation course is aimed at technicians, manufacturers, designers, managers, quality inspectors and engineers who need a comprehensive understanding of current and progressive pre-preg manufacturing processes. The course supports delegates from across a wide range of industries including automotive and wind turbines through to sports equipment and prosthetics.

This industry driven course is designed to reflect the correct use of modern pre-preg laminating production techniques, incorporating up to date manufacturing and processing methods. Starting from a base of well-established techniques, the course gradually progresses through using co-bonding, co-cure and multi part component assembly. The course explores in detail the use of the latest manufacturing technologies and fabric architectures to develop an understanding and competence in the use of state-of-the-art laminating techniques developing self-sufficiency and confidence in the application of pre-preg techniques. By combining manufacturing know how including reusable bagging, inflatable consolidators, intensifier forms, bladders, elastic consolidators and form stiffeners, the course is reflective of the advancing changes and industrial practices needed to keep ahead of competition.
Delegates produce a range of composite using a variety of material architectures and manufacturing techniques.

The course will cover:

  • Review health, safety and handling.
  • Composite terminology, materials structure, properties and performance characteristics.
  • Examining fibres, fabrics and drape.
  • Resin types, properties storage, shelf life and disposal.
  • Thermal mapping, curing considerations exotherm and Tg impacts.
  • Techniques and equipment requirements and the drivers for change.
  • Tooling care, preparation and release agents.
  • Templating, nesting and kitting for effective manufacture and material life management.
  • Consideration and practices for joining placement techniques and methods to maintain load distribution.
  • Debulking when and how.
  • Vacuum bagging.
  • Practices for convex parts including the effects of draping.
  • Pre-preg manufacturing of internal and external corners, radii, returns and ply drop offs.
  • Use of a working tool in the manufacture of a two-part cellular component with various curing temperatures.
  • Laminating into female tool incorporating joggle techniques.
  • Utilisation of inserts and multi-staged curing on caul and complex components.
  • Use of an internal intensifiers in the manufacture of thin walled component.
  • Consideration of the impact of current tooling design on the selection of processing and material component options.
  • Impact of manufacturing process on surface finish.
  • Out of autoclave manufacturing.
  • Inspection and defect identification.

3rd – 7th June 2024
25th – 29th November 2024

Pre-Preg Laminating Stage 2

Course Code: 012
Duration: 5 Days
Course Fee: £1086 +VAT
Course structure: 20% theory, 80% practical
Prior learning (Pre-requisite): 011 Pre-Preg Laminating Stage 1.

This progression course is aimed at those who are processing pre-pregs including core materials and different resin systems. Those people working as technicians, manufacturers, designers, managers, quality inspectors and engineers within the composites pre-preg industries will benefit from this course which will allow the delegate to develop an in-depth understanding of laminating opportunities and issues for effective product and production methods.

This continuously improving industry driven course is designed to reflect the correct use of modern pre-preg laminating production techniques, incorporating up to date manufacturing and processing methods. Expanding on the knowledge developed in the Pre-Preg Laminating Stage 1 course this course develops the requirements for bonding and mechanical fastening, issues associated with complex shapes and the latest rapid cure pre-preg systems along with techniques for shaping and using different core materials. This course introduces state of knowledge processes for the creation of composites. Delegates will have the opportunity to produce a range of composite using a variety of material architectures and manufacturing techniques.

The course will cover:

    • Review of Health and Safety issues, resins and prepregs.
    • Sandwich panel theory, core materials and their use.
    • Review of adhesive bonding, co-cure and co-bond.
    • Review of moulding methods male, female moulds, tooling effects, undercuts.
    • Optimisation of current state of knowledge mould release systems for various mould and resin systems with consideration against manufactures recommendations.
    • Use of foam and honeycomb as spacer layers in flat and curved components with flat and chamfered edges; consideration of corner intensification, formation and joining considerations to avoid bridging affects. Cured by oven, PLC and inferred heat application.
    • Core and pre-preg reinforcements for load attachment
    • Bonding and laminating composites with integral attachment points.
    • Co-cure and Co-bonding approaches to part production and dual vacuum bagging.
    • The optimisation of fabric architecture in complex lamination forms.
    • Utilisation of intensifiers for intricate forms in prototype production.
    • Use of open, closed and mould return linked to effect upon bonding and surface finish.
    • Formalisation of pre-preg systems and their application reason for low to high temperature lamination systems.
    • The effect of vacuum and heat application during the cure process on defect formation, the effectiveness of vacuum seal technologies.
    • The use of different resin systems and application of purpose formulated rapid cure pre-impregnated system.
    • The creation and application of vacuum intensifiers for internal and external application
    • Aesthetics in design templating and their use.

24th – 28th June 2024