Advanced Composites - Design Manufacture and Engineering (DME)
Damian Cianci instructs this robust training course to educate students in the advanced principles used throughout the composite industry. Located in the heart of Northwest aerospace, Damian has been proud to work with all the local technicians and engineers for many years.
The Composite Technician Certificate was developed many years ago and we use this as our starting point to provide a great introduction into the field. The certificate covers all the important basics regarding composites manufacturing and repair. We quickly move beyond this into advanced materials and methods used throughout much of the industry. For training material we closely follow the FAA guidelines but have many other valuable sources as well. The majority of our students in the various Applied Science and Manufacturing courses are aerospace employed technicians and engineers they bring to us current and specific knowledge of processes and materials used throughout the area. Beyond that, we continually look into other fields besides aerospace to see what their challenges are. Marine and automotive are big players but with the continued technology expansion and new companies in the game, knowledge and creative uses of composite materials are spreading fast.
Damian continually develops this course as new technology emerges. He's has been teaching technology and manufacturing courses with the college for over fourteen years and his delivery of this program has received many accolades from the aerospace community and has helped many students find employment in the aerospace composite field.
For several years this course has met all the prerequisites (Green lights) for the Boeing composite repair job and is listed as acceptable training for the Boeing composite apprenticeship program.
Important points for those looking to enroll:
Entry level course - No prerequisites Several Labs - Almost daily - Lecture and labs integrated Class meets twice a week - 3 hour sessions - day and night classes
The Objectives:
COMPOSITES TECHNICIAN CERTIFICATE
Introduction to Composites Materials
Unit 1: Why Composites? Unit 2: Fibers Unit 3: Resins Unit 4: Core Unit 5: The Interface and Surface Preparation Unit 6: Safe Handling of Materials Unit 7: MSDS
FRC:Manufacturing
Unit 1: Wet Hand Lay-up, Vacuum Bagging, Ply Cutting, Autoclaves and Ovens Unit 2: Liquid Composite or Infusion Molding Unit 3: Filament Winding and Automated Tape Lay-Up Unit 4: Compression Molding and Pultrusion Unit 5: Safety
FRC:Repair
Unit 1: Classification of Damage Unit 2: Inspection and Documentation of Damage Unit 3: Repair Techniques Unit 4: Advanced Repair Techniques
ADVANCED COMPOSITE FABRICATION AND REPAIR
This course goes beyond the skills and methods learned in the introductory certification section to include any new technologies, methods and advanced skills
Objectives and Labs:
Product Lifecycle Management How this pervades all levels of manufacturing
Basic math skills Algebra, trigonometry, fractions, ratios Math applied to real shop needs
Further mold making techniques Fiberglass With and without vacuum bag Molding plaster Polyurethane (foam and solid) Aluminum (CNC milled)
Introduction to CATIA and 3D Modeling Used to design tooling for composite mold making
Mold post preparation (primarily for use with cheaper tooling) MDF sanding and epoxy finish Foam fiberglass coating and polishing
Laminate Labs Comparison of various laminate structures Core vs no core Material comparison carbon, aramid, glass Ply orientation comparison Stress analysis of all these structures Longitudinal deflection, compression, torsion, shear, peal, and tension Bring to failure and save broken parts for later lab
Infusion labs Vacuum infuse a 3 ply carbon fiber panel Save part for later lab
Filament winding / roll wrapping lab Use a small 3D printed tool to make a filament wound part
Honeycomb with carbon fiber prepreg lab Manufacture a small floor panel Hot bonder programming and operation Save part for later lab
Repair labs Laminate ply sanding practice Use pieces of the infusion lab panel Damage repair Repair all broken coupons from the laminate lab Honeycomb floor panel repair Use part from lab More use of hot bonders