Advanced Polymer Composite Manufacturing Techniques Training

Objectives:
• Understand the definition and classification of polymer composites
• Identify key properties and advantages of composite materials
• Recognize common applications in various industries
• Distinguish between thermoset and thermoplastic matrices

Topics:
• Overview of composite materials
• Matrix and reinforcement roles
• Types of polymer matrices (thermoset vs thermoplastic)
• Reinforcement forms (fibers, fabrics, mats)
• Property enhancement mechanisms
• Industry applications (aerospace, automotive, marine)
• Environmental and sustainability considerations

Objectives:
• Describe the chemistry of thermoset resins (epoxy, polyester, vinyl ester)
• Explain curing mechanisms and their effect on properties
• Understand fiber types (glass, carbon, aramid) and their characteristics
• Apply selection criteria for matrix-fiber combinations

Topics:
• Thermoset resin chemistry and curing
• Thermoplastic matrix characteristics
• Glass fiber types and properties
• Carbon fiber types and properties
• Aramid and specialty fibers
• Fiber surface treatments and sizing
• Material selection criteria
• Health and safety handling of raw materials

Objectives:
• Identify different preforming methods
• Describe manual layup processes and their applications
• Understand the importance of fiber orientation
• Recognize defects in layup and their causes

Topics:
• Preforming techniques (cutting, stacking, stitching)
• Manual hand layup process
• Spray-up method
• Fiber orientation and laminate stacking sequence
• Common layup defects (wrinkles, voids, misalignment)
• Quality checks during layup
• Tooling and mold preparation

Objectives:
• Explain the vacuum bagging process and its benefits
• Set up a vacuum bagging system correctly
• Monitor cure cycles and parameters
• Troubleshoot common vacuum bagging issues

Topics:
• Vacuum bagging components (bag, sealant tape, breather, release film)
• Bagging procedure step-by-step
• Vacuum pressure and leak detection
• Cure cycles (room temperature vs elevated temperature)
• Oven and autoclave curing
• Post-cure processes
• Troubleshooting bagging defects

Objectives:
• Understand the principles of resin infusion
• Describe vacuum-assisted resin transfer molding (VARTM)
• Select appropriate infusion materials
• Identify process parameters affecting infusion quality

Topics:
• Introduction to liquid composite molding
• VARTM process overview
• Resin infusion setup (inlet, outlet, distribution media)
• Resin flow dynamics and permeability
• Process parameters (vacuum level, resin viscosity, temperature)
• Infusion defects (dry spots, race tracking)
• Materials for infusion (resins, flow media, peel ply)

Objectives:
• Define prepreg materials and their advantages
• Handle and store prepregs correctly
• Lay up prepreg laminates
• Cure prepreg components using autoclave or oven

Topics:
• Prepreg manufacturing process
• Types of prepregs (unidirectional, woven)
• Storage requirements (cold storage, out-time limits)
• Cutting and kitting prepregs
• Automated layup (AFP/ATL) introduction
• Hand layup of prepregs
• Autoclave curing cycle
• Quality control for prepreg parts

Objectives:
• Describe compression molding process
• Understand bulk molding compound (BMC) and sheet molding compound (SMC)
• Set up compression molding parameters
• Identify typical defects and their remedies

Topics:
• Compression molding machine components
• BMC and SMC material forms
• Mold design and heating systems
• Process parameters (temperature, pressure, dwell time)
• Flow behavior in the mold
• Defects (short shots, porosity, warpage)
• Applications in automotive and electrical industries

Objectives:
• Explain the filament winding process
• Identify winding patterns and their applications
• Set up winding parameters
• Understand mandrel design and removal

Topics:
• Filament winding machine types
• Winding patterns (helical, hoop, polar)
• Fiber tension control
• Resin bath and impregnation
• Mandrel materials and design
• Curing and mandrel removal
• Applications (pipes, pressure vessels, tanks)

Objectives:
• Describe the pultrusion process
• Understand die design and heating zones
• Identify reinforcement forms used in pultrusion
• Recognize quality issues and process control

Topics:
• Pultrusion line components (creel, resin bath, die, puller)
• Die design and heating zones
• Reinforcement forms (rovings, mats, veils)
• Resin systems for pultrusion
• Process parameters (pull speed, temperature, curing)
• Defects (voids, surface defects, fiber breakage)
• Applications (profiles, beams, gratings)

Objectives:
• Understand 3D printing technologies for composites
• Describe fused filament fabrication with continuous fiber
• Identify design considerations for additive manufacturing
• Evaluate post-processing requirements

Topics:
• Overview of additive manufacturing
• FFF with continuous fiber reinforcement
• Short fiber reinforced filaments
• Stereolithography with ceramic composites
• Design for additive manufacturing (DFAM)
• Post-processing (curing, surface finishing)
• Applications (prototyping, tooling, end-use parts)

Objectives:
• Compare adhesive bonding vs mechanical fastening
• Design bonded joints for composite structures
• Perform surface preparation for bonding
• Understand welding techniques for thermoplastics

Topics:
• Adhesive types (epoxy, acrylic, polyurethane)
• Joint design (lap, scarf, butt)
• Surface preparation methods (abrasion, plasma, chemical)
• Mechanical fastening (bolts, rivets, inserts)
• Hybrid joining
• Ultrasonic and induction welding
• Quality assurance of joints

Objectives:
• Identify common defects in composite manufacturing
• Apply non-destructive testing (NDT) methods
• Interpret NDT results
• Understand statistical process control (SPC)

Topics:
• Defect types (delamination, porosity, foreign inclusions)
• Visual inspection and tap testing
• Ultrasonic testing (A-scan, C-scan)
• Radiography (X-ray, CT)
• Thermography and shearography
• Destructive testing (microscopy, mechanical tests)
• Statistical process control basics
• Documentation and traceability

Objectives:
• Assess damage in composite structures
• Select appropriate repair methods
• Perform scarf and patch repairs
• Understand repair certification requirements

Topics:
• Damage assessment (impact, delamination, moisture)
• Repair design principles
• Scarf repair procedure
• Patch repair (precured, wet layup)
• Bonded vs bolted repairs
• Curing of repairs (heat blankets, lamps)
• Repair validation and testing
• Regulatory and certification aspects

Objectives:
• Apply design principles for composite manufacturing
• Use CAD tools for composite layup design
• Optimize laminate stacking sequence
• Consider cost and producibility in design

Topics:
• Design for manufacturing principles
• Laminate design (orientation, thickness, ply drops)
• CAD software for composites (CATIA, FiberSIM)
• Ply book generation
• Draft angles and radii
• Tooling considerations
• Cost estimation
• Design review and iteration

Objectives:
• Understand the role of simulation in composite manufacturing
• Model resin flow and cure using software
• Predict process-induced defects
• Interpret simulation results for process optimization

Topics:
• Introduction to composite process simulation
• Resin flow modeling (Darcy's law, permeability)
• Cure kinetics and heat transfer
• Stress and deformation during curing
• Software tools (PAM-RTM, COMPRO, Abaqus)
• Validation of simulations
• Optimization of process parameters

Objectives:
• Identify automation technologies in composite manufacturing
• Understand robotic pick-and-place and AFP/ATL
• Implement sensors and data acquisition
• Apply Industry 4.0 concepts to composite production

Topics:
• Automated fiber placement (AFP)
• Automated tape laying (ATL)
• Robotic pick-and-place for preforms
• In-process monitoring (cure sensors, flow sensors)
• Data acquisition and statistical process control
• Digital twin concept
• Smart factories and IoT
• Case studies of automated lines

Objectives:
• Select materials for composite tooling
• Design molds for different processes
• Understand thermal expansion and CTE mismatch
• Apply surface finishing and release agents

Topics:
• Tooling materials (steel, aluminum, invar, composite)
• Mold design for RTM, infusion, compression molding
• Thermal management (heating channels, insulation)
• Coefficient of thermal expansion (CTE) considerations
• Surface preparation and mold release
• Vacuum integrity and sealing
• Tooling cost and durability

Objectives:
• Identify hazards in composite manufacturing
• Implement control measures for chemical exposure
• Manage waste and recycling
• Comply with South African OHS and environmental regulations

Topics:
• Chemical hazards (resins, hardeners, solvents)
• Personal protective equipment (PPE)
• Ventilation and containment
• Fire safety and storage of flammable materials
• Waste management (resin waste, scrap fibers)
• Recycling of composites (mechanical, thermal, chemical)
• South African OHS Act and regulations
• Environmental management systems (ISO 14001)

Objectives:
• Explore nanocomposites and their manufacturing
• Understand bio-based composites
• Review self-healing and smart composites
• Discuss future trends in composite manufacturing

Topics:
• Nanocomposites (CNT, graphene reinforcement)
• Bio-based resins and natural fibers
• Self-healing composites
• Smart composites with embedded sensors
• 3D woven and braided preforms
• Hybrid manufacturing (additive + subtractive)
• Recycling technologies for composites
• Industry trends and research directions

Objectives:
• Integrate knowledge from all modules
• Develop a manufacturing plan for a composite part
• Present and defend the plan
• Review key concepts and assessments

Topics:
• Capstone project brief
• Part selection and material choice
• Process selection and tooling design
• Quality plan and cost estimate
• Team presentations and peer review
• Instructor feedback
• Course review and key takeaways
• Final assessment and certification