Composites Technology

SHOP SAFETY AND TOOL USE
Students learn required safety practices and operating standards for stationary power tools, hand tools, and composites related materials. These issues are framed with an understanding of applicable Federal and State safety standards. Included is the fitting and use of personal protective equipment, specific machine safety, hazardous waste handling, and fire prevention procedures.  

COMPOSITES APPLICATIONS LAB OPERATING PROCEDURES
This course establishes the basic materials handling and shop procedures that will be used throughout the program including materials handling basics such as measurements and mixing ratios, use of lab balances, and laminating specific tools. The fabrication of open molded panels consolidates the above learning with the student’s first demonstrated creation of a composites laminate.

MOLDING PROCESS DESIGN-BUILD PROJECT
Once fundamental materials handling skills are established, this course challenges students with a fun "conceive, design, build" project. Students are tasked with designing and constructing a manually powered filament winding machine using a specified kit of materials. The goal is to produce a hand-built machine that produces a fiberglass tube. This tube will then be load-tested to failure and produce a number of “lessons learned.” The process will involve a sequence of conceptualizing, building a prototype, testing and revising that leads to a workable machine and improvement of the process.

OPEN MOLDING TECHNOLOGY
Open molding is the bedrock process from which all other composites processing methods are derived. This includes the use of basic laminating tools and understanding the handling of resins and fiber reinforcements. The course introduces the use of gel coat as an in-mold coating and the use of various configurations of glass fiber reinforcement. Student gain proficiency in mold surface preparation, spray equipment operation and spraying techniques, gel coat application, resin application, laminate fabrication and the use of sandwich core materials.

COMPOSITES REPAIR AND REFINISHING
Students gain experience in the identification of cosmetic defects and structural damage to composite structures. The identification of various types of surface cracks, and the forces involved in creating those cracks, is highlighted to form an analysis of the failure mechanism. Cosmetic repairs include surface preparation, use of gel coat and finish sanding/polishing techniques. Structural repairs begin with an understanding of damage removal and scarfing techniques for laminate restoration. Exercises include impact testing of laminated panels, damage identification and analysis, structural remediation and finishing.

INTRODUCTION TO COMPOSITES TOOLING
Tooling consists of patterns and molds used for the production of composites parts. Student begin with the hands-on building of a basic pattern or model that is shaped and finished to subsequently produce a composites mold. This manual creation of a pattern and mold establishes the platform for understanding the fundamental concepts of moldmaking including the concept of the positive and negative geometries of the
pattern and mold. 

FUNDAMENTALS OF COMPUTER AIDED DESIGN (CAD 3D MODELING)
This course introduces the use of CAD drawings using Rhinoceros (Rhino 5) design modeling software. With the development of CAD modeling skills, students will learn to create 3D models for the purpose of illustrating an object and providing digital output that can be used to produce actual physical artifacts via Computer Numeric Control (CNC) and Rapid Prototyping (3D Printing). Students will learn the software interface, tool-set use, and best practices.

COMPUTER NUMERIC CONTROL (CNC) ROUTER MACHINING
The ability to machine low-cost patterns or to directly build molds has become a disruptive technology within the realm of composites toolmaking. Based on previously learned CAD drawing, students will deveLop an understanding of CNC router operation. This includes translating a 3D drawing model to machine code (G-code) using RhinoCam software to program tool paths for machining patterns or molds. Students will gain experience with the CNC router operation, the machine coordination system, and setting up machining projects. 

VACUUM BAG MOLDING PROCESS
Students learn how to use atmospheric pressure to enhance the composites molding process and improve the mechanical properties of a laminate. Students will be introduced to the principles of vacuum, vacuum related nomenclature, and effects of negative
pressure (vacuum) in molding operations. Students will learn the elements of a vacuum bag system such as the use of peel ply, breather, vacuum transmission, sealant tape and bagging film. Experiential skills will be developed in the methods of fabricating vacuum bags with a concentration on proper bag sizing, creation of pleats, installation of vacuum ports, and leak detection and remediation.

VACUUM INFUSION MOLDING PROCESS
This molding process is widely used in the aerospace, marine, wind energy, and other high
performance industries. Students will develop experience with fabricating infusion bags using release ply, flow media, and setting up resin and vacuum flow channels. Skill development includes resin calculations, advanced vacuum bag configuration, infusing monolithic (single skin) laminates, infusing sandwich construction laminates, controlling flow rate with vacuum pressure and troubleshooting the process.

ADVANCED COMPOSITES PREPREG MOLDING PROCESS
This process is used to create the lightweight, high strength structures found in aerospace, marine, motorsports and other advanced industries. These oven cured epoxy/carbon fiber laminates produce the light and extremely robust structures used in a variety of high performance applications. Students are introduced to pre-impregnated (prepreg) advanced fiber and resin matrix materials, and the elevated temperate cure mechanism for these laminates. In the classroom, the basic chemistry of epoxy resins and properties of advanced fibers (carbon, KevlarTM and others) are highlighted, along with the properties of prepreg materials. Basic prepreg processing begins with the fabrication of panels with varying fiber orientations to illustrate the effects balanaced and unbalanced laminates. As experience is gained, increasingly complex layups and fiber orientations are established. The course elements include:

•Matrix and fiber technologies in advanced composites
•Design considerations of advanced composites
•Molding methods and practices
•Core material applications
•Tooling for advanced composites
•Inspection and testing procedures
•Bonding and fastening of advanced composites

Students will conceive, design, and implement a project that creates a composites product. Through a process of discovery and discussion with instructors, students choose from an array of options and select a project based on their personal interests, capabilities, and other criteria.

Examples of previous capstone projects include surfboards, snowboards, auto components, paddles, ship models, lacrosse sticks, and small scale wind turbines.

The capstone project process includes:

• Conceptualizing potential projects
• Determining feasibility – complexity and skill, facility capability, materials, cost and time
• Initial project proposal, defending the concept and developing feasibility
• Developing a project management plan including cost/labor estimates
• Translating the concept into a CAD 3D model
• CNC machining patterns, molds or components
• Molding composites components
• Assembling components and finishing details
• Testing product function
• Submitting project for evaluation

The capstone project is the consolidation of the skills learned throughout the program. It becomes a valuable real-world experience that introduces the student to the process of ideation, problem solving, and hands-on application. These demonstrated skills are much sought after attributes in the employment arena.

The capstone project provides the jumping off point to a month-long externship in the composites industry, and becoming uniquely positioned for a job and a career in a rapidly advancing industry. The externship is facilitated through Career Development and provides the opportunity for students to apply the skills they've acquired in the shop to the workplace while gaining valuable business, resume-building, and hands-on experience:

• Resume writing 
• Industry research
• Interviewing & professional communication
• Application of craftsmanship & technical skills in a business environment
• Relationship building with employers 

Learn more about the IYRS externship program here.