Elements and Performance Criteria

This competency unit includes the use of equipment and materials to form moulds for composite products.

Procedures means all relevant workplace procedures, work instructions, temporary instructions and relevant industry and government codes and standards.

The processes covered by this unit include, but are not limited to:
construction of moulds
use of composites materials including gel coats, resins and fibres.

This competency includes tools and equipment such as:
plugs/patterns
hand tools and power tools for use with composite and other materials such as metal and timber
hand mixing equipment and stirrers
hand application tools, rollers
relevant personal protective equipment.

Typical hazards include:
hand and power tools
temperature
hazardous materials
manual handling hazards
equipment operations.

Typical process and product problems include:
structural strength, rigidity and durability of the mould
dimensional accuracy of the mould
placement of flanges, closures and fitments
attachment of substructures.

Specifications may include:
engineering drawings or model/product.

All operations are performed in accordance with procedures.

Essential knowledge and enterprise requirements
Knowledge of the enterprise's procedures and relevant regulatory requirements along with the ability to implement them within appropriate time constraints and work standards.

Essential knowledge may include:
polyester resin materials knowledge: basic ingredients and their functions; types and uses; grades; fillers; shelf life; storage and safety; cure process; exotherm graph; factors affecting the cure process; post curing
epoxy resin materials knowledge: uses; cure reaction; exotherm graph; effects of temperature; effects of hardener; advantages and disadvantages; safety precautions
vinylester resin materials knowledge: uses; cure reaction; catalyst/promoter systems, types and effects; advantages and disadvantages compared with other resins; safety precautions
dicyclopentadiene (DCPD) - filled resin system, e.g. Reichhold
catalysts and promoters materials knowledge: terminology; types; grades; uses; storage and safety.
reinforcements materials knowledge: basic characteristics and property differences of E Glass, S2 Glass, Carbon, Aramid; formulations; manufacture; terminology; types of finish and binders; common weights available; resin to glass ratios; glass content and comparative strength of the basic forms; the effect of increasing fibre content on reducing thickness and flexural properties; basic effect of proportion and direction of fibre orientation.

Competence includes the ability to:
apply and/or explain:
selection of materials for mould construction
steps in the construction process
aspects of the mould construction to meet the dimensional and production requirements of the mould
key requirements of the product which impact on the mould construction
hazards of the materials and process and appropriate hazard control procedures
products, materials and material characteristics
safety procedures and the use of PPE in relation to handling materials, equipment operation and cleanup
impact of variations in raw materials and equipment operation in relation to final product
use PPE, safely handle products and materials, read relevant safety information and apply safety precautions appropriate to the task
distinguish between causes of faults such as:
wrong materials for the mould construction
materials incorrectly used
lack of rigidity of the mould
contaminated materials.

Critical aspects
It is essential that competence is demonstrated in the ability to complete moulds to specifications.

Language, literacy and numeracy requirements
This competency requires the ability to communicate with a wide range of personnel and to interpret product specifications and mould requirements.
Numeracy is required to the level of determining required weights/volumes of materials in a resin mix for different circumstances (say using a data sheet), number of layers of impregnated matrix required to yield the required product laminate thickness, and similar activities.

Assessment method and context
Competence in this unit may be assessed:
on an operating plant allowing for operation under all normal and a range of abnormal conditions
by use of a suitable simulation and/or a range of case studies/scenarios
by a combination of these techniques.

In all cases it is expected that practical assessment will be combined with targeted questioning to assess the underpinning knowledge and theoretical assessment will be combined with appropriate practical/simulation or similar assessment.

Resource implications
This section should be read in conjunction with the range of variables for this unit of competency. Resources required include suitable access to an operating plant or equipment that allows for appropriate and realistic simulation. A bank of case studies/scenarios and questions will also be required to the extent that they form part of the assessment method. Questioning may take place either in the workplace, or in an adjacent, quiet facility such as an office or lunchroom. No other special resources are required.