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DMSC56
Pre-preg Mould Making

Typical Attendees
This course is suitable for anyone involved with processing pre-preg moulds, including pre-preg laminators, technicians, supervisors, engineers & designers.

Structure
30% theory, 70% practical, 10 delegates maximum, no experience required



Pre preg mould making course content

DMSC56 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

Theory

Introduction to composites theory, matrix, reinforcing & fabric materials
Theory
Pre-preg materials
Pre-preg processing

Theory
Tooling and component design principles
Pattern & mould materials
Thermal expansion
Spring back & distortion
Theory, Demo & Practical
Release agents Release pattern
Pattern checking & Preparation of a two part pattern

Demo
Fitting pattern split/joint boards, shaped locators and bush locating dowels
Theory, Demo & Practical
Production of pre-preg moulds using the tile method
Handling, preparation & application of low temperature pre-preg
Lay-up first ply of first part of a two part tool using tiled materials
Tuesday Theory
Vacuum bagging
Materials & application methods
Leak detection
Vacuum de-bulking

Demo & Practical
De-bulk first ply of single part tool
Practical
Complete lay-up of first part of a two part tool including orientated & tiled plies, double curvature, internal corners, draping, vacuum de-bulks and balancing final ply
Final de-bulk
Theory, Demo & Practical
Low temperature pre-preg curing
Temperature &,pressure profiles
Vacuum bagging for autoclave curing
Cure first stage of two part tool
Wednesday Demo & Practical
Remove split board and prepare pattern for second stage of two part tool
Theory & Demos
Templated balanced, orientated plies & ply joins for tooling

Practical
Template & nest plies for second mould half
Demo & Practical
Production of second part of a two part pre-preg mould, including application of templated, orientated and balanced plies, fitting drill/bolting bushes, vacuum de-bulks & cure vacuum bag
Thursday Theory, Demo & Practical
De-bag & break out split mould tools
Cleaning & assembly of mould tools
Theory, Demo & Practical
Post-curing of moulds
Tg points

Theory & Discussion
Alternative Pre-preg tooling systems
Demo & Practical
Lay-up single part tool using alternative pre-preg tooling systems, bushes, dowels, stiffening flanges, vacuum bagging & autoclave curing
Friday Theory, Demo & Practical
Safe edging, flash,removal and surface finishing of moulds
Sealing & release,moulds produced
Theory, Demo & Practical
Tooling modificationsMould stiffening
Loose tooling
Return & nett edge tooling
Theory & Discussion
Causes of & identifying defects
Final inspection of parts produced
Reinstate Workshop
Written test
Equipment return
Summary /Feedback
DMSC54-56 Prepreg Courses.pdf
File Size: 181 kb
File Type: pdf
Download File



This course is suitable for anyone involved with processing pre-preg moulds, including pre-preg laminators, technicians, supervisors, engineers & designers. We cover approximately 28 hours of practical throughout the week.

Pre-preg mould making begins with pattern, mould and component design principles. You will learn about undercuts/lock-on conditions, join lines, pattern and mould materials, thermal expansion and distortion. These concepts are applied in the manufacture of your two part mould.

As the week progresses we introduce more theory and technical detail.

Your first pattern design will include split/joint boards, shaped locators and bush locating dowels. You will release and check it for damage, and accuracy of split board fit, before beginning laminating.
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The first mould is laid up using the tile method. During the practical task you will be shown the importance of staggering your butt joins and having a layup strategy to follow. You will use vacuum bag debulks at set points during the laminating as the plies are built up. These debulks will improve the accuracy and quality of your laminate. You will be shown the best application of suitable vacuum bagging materials and how to detect leaks. Once the first mould is completed it is cured in the autoclave.

You will lay up the second mould using the templating method. Beginning by removing the split boards from the first mould and then preparing the pattern and mould for laminating. You will template and cut out your plies, allowing for orientation and balancing of the layup. The completed layup is envelope bagged and cured in the autoclave.

Pre-preg mould making
The final mould to be produced is a single part mould using an alternative pre-preg tooling system. Bushes are used and located on dowels as well as stiffening flanges. The mould is vacuum bagged and cured.

All of the cured moulds are broken off the patterns and post cured. The moulds are then safe edged, surface finished, sealed and released ready for production. We end the course with group discussion, inspection of the parts, identifying issues and possible solutions
UPCOMING COURSES

DMSC60, Producing Your Own Composite Parts
12-16 May 2025


DMSC61, Composite for Engineers & Designers Stage 1
9-13 June  2025


DMSC62, Composite for Engineers & Designers Stage 2
16-20 June  2025

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dark matter composites ltd
Tel/Fax:  +44 (0)1582 791001
email: 
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