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DMSC61
Composites for Engineers and Designers,
Stage 1 Materials & Processes

This is our most intensive and in-depth course covering current composite materials and processes. It provides an honest and open insight into working with composite materials. The sessions are informative, interactive and thought provoking. The key focus is on component design principles, production considerations and controls to form an intuitive and creative approach to composite engineering.

Typical Attendees / Pre-requisite
This is a high end course and delegates will need to have a sound technical background in materials, engineering or design, or have relevant experience, please call or email us if you are unsure which course is best for you.


Structure
60% theory, 40% practical, 10 delegates maximum, no experience required


Course Dates
27 February - 3 March 2023
11-15 September 2023
Price per Delegate
£ 1,920.00     (£ 1600.00 plus £320.00 VAT)


Composites for engineers and designers 1 course content
DMSC61 Session 1
09:00 - 11:00
Session 2
11:15 - 13:15
Session 3
13:45 - 15:45
Session 4
16:00 - 18:00
Monday Introduction
Equipment issue
Health & Safety

Measures & Legislation

Theory & Discussion
Composites history
Composites theory
Theory & Discussion
Matrix materials
Reinforcing materials
Fabric types
Laminate theory and ply orientation
Lay-up specifications
Theory & Discussion
Sandwich structures
Core materials
Processing composite materials

Theory & Practical
Tooling care and preparation
Release agents
Theory & Guided Practical
Wet lay up laminating
Design a laminate to suit a load requirement
Production of a wet lay-up part including calculations, gel coat & laminate application
Tuesday Theory
Resin flow & film infusion laminating
External & internal media with vacuum bagged & closed moulding

Demo & Practical
Trial panels & evaluation
Theory & Discussion
Vacuum bagging
Bagging materials & methods
Leak detection

Guided Practical
Design of distribution media for resin flow infused part
Guided Practical
Gel coating, application of fabrics, external distribution and infusion media, surface vacuum bagging and leak detection of resin flow infusion part
Practical & Discussion
Resin calculations
Predicting flow fronts & infusion times
Final resin flow infusion and evaluation of parts

Demonstration
Resin film infusion laminating
Wednesday Theory, Demo & Guided Practical
Pre-preg laminating
Material templating ply orientation, nesting & kitting
Design a laminate to suit a load requirement
Theory
Processing & preparation of core materials

Guided Practical
Pre-preg laminating of part with sandwich structure
Demo & Practical
Envelope vacuum bag & cure pre-preg part

Theory
Matrix curing & post-curing, temperature & pressure profiles
Tg points
Theory & Videos
Resin transfer moulding
Hot press moulding
Filament winding
Pultrusion
Automated tape laying & fibre placement
Thursday Theory & Discussion
Causes of and identifying defects
Manual & NDT inspection
Production & quality controls
In-service monitoring
Theory, Demos & Practical
Breakout parts produced
Trimming & finishing composites
Theory & discussion
Adhesion & bonding methods

Theory & Demos
Failure modes
Re-work & repair principles
Repair techniques
Guided Practical
GRP and pre-preg repair including removal of damage, preparation of the repair surface & laminating of repairs

Reinstate Workshop
Friday Theory & Discussion
Tooling and component design principles, types materials & life
Re-cycling & environmental issues
Practical & Discussion
Case studies for tooling and component designs & problem solving
Theory & Discussion
Laminate calculations
Finite element analysis
Testing composites
On-line resources
Written test (1hour)
Equipment return
Summary / Feedback
DMSC61 & 62 Composites for engineers & designers courses.pdf
File Size: 213 kb
File Type: pdf
Download File

Although no previous composites experience is required for this course you will need to have a sound technical background in materials, engineering or design, or have relevant experience. Understanding and applying the design principles for the various composites materials and processes is the primary focus on this course.

The course will give you an intensive and technical overview whilst providing an intuitive approach to composites that forms a strong foundation to develop from.

During the theory sessions we will introduce the manual composites processing methods starting with wet lay-up, then infusion and finally pre-preg.

Engineers Composite courses
Picture
We look at how wet lay-up is used and the characteristics of the process. You will then be given a design brief and supplied with materials. Your task is to meet the specification and make the part applying what you understand of the materials. These parts are laid up by hand with brushes and rollers to wet out and consolidate the materials.

After this we move onto a resin infusion task.  Following the theory session, you will work in groups to produce a trial panel using the flow infusion method. Each group will work with different external infusion media and either stitched, bonded or woven fabrics. The results from the trial panel are discussed and used to design an infusion strategy for the final component.


The final process you will use is pre-preg laminating.  This encompasses a new range of skills and builds on from the theory of the previous composite processes. We will look at the importance of pre-preg material handling and preparation which includes defrosting, producing templates, nesting, kitting materials and ply orientation. At this stage composite sandwich structures are introduced adding an additional range of properties to consider in the design of another part. These parts are envelope bagged and cured in an autoclave.

Curing theory allows you to programme your own autoclave cure cycle. Interpreting information from the technical data sheet you will be able to produce a suitable heat and temperature cure profile, allowing for a glass transition temperature (Tg) for in service use.

Automated processes are covered in the classroom with the aid of videos and theory. Each process; resin transfer moulding, hot press moulding, filament winding, pultrusion, automated tape laying and automated fibre placement is explained highlighting their applications, limitations and advantages.

The components that have been produced are broken out of the moulds, trimmed and inspected. As a group you will discuss the components to fully understand where mistakes have been made, and how they could have been prevented. From basic manufacturing defects to design errors, this session brings together the work covered so far.


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Testing composite repairs
We move onto failure modes and repair techniques, gain an understanding of the types of damage composite components suffer and introduce controlled damage into parts. The damaged material is removed and a scarf repair is used to make good the impaired area.

The final day of the course brings together all of the principles covered in the week, in relation to the design of composite tooling and parts, using case studies to demonstrate the concepts used in composite design.


This course will accelerate anyone’s knowledge and understanding of composites and will aid in technical communication in the composites arena.
UPCOMING COURSES


27th Feb - 3rd March 2023 - DMSC61

6th-10th March 2023 - DMSC58

27th - 31st March 2023 - DMSC53

15th -19th May 2023 - DMSC51

12th - 16th June 2023 - DMSC60

click here for composite training  information

dark matter composites ltd
Tel/Fax:  +44 (0)1582 791001
email: 
info@darkmattercomposites.co.uk
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