Back to Course

Composite Materials 1: Manufacturing and Production

0% Complete
0/0 Steps
  1. INTRODUCTION

    Meet the Instructor
  2. The Course
  3. WHAT IS A COMPOSITE?
    Definitions
  4. Types of resin
  5. Types of resin and coatings
  6. Types of fabrics
  7. Types of cores
  8. APPLICATIONS
    Applications
  9. MANUFACTURING METHODS
    By hand
  10. Infusion
  11. Prepreg
  12. Pultrusion
  13. RTM
  14. Autoclave
  15. How to select the right procedure
  16. MOULD DESIGN AND REQUIREMENTS DEFINITION
    Selection of the reference (good) surface
  17. Demoulding analysis & mould divisions
  18. Technical flange
  19. Assemblies
  20. Airtightness
  21. Operational features: Pressure
  22. Operational features: Durability
  23. Operational features: Surface Finish
  24. Operational features: Tolerances
  25. Operational features: Support Structure
  26. Operational features: References
  27. PARTS MANUFACTURING
    Main differences between mould and part manufacturing
  28. Process selection
  29. Production design
  30. Laminate details
  31. Bonding details
  32. Quality control and inspection
  33. Repair and rework philosophy
  34. Documentation and traceability
  35. APPLICABLE TESTS
    Visual inspection and defect recognition
  36. Dimensional control
  37. Non-destructive testing
  38. Airtightness
  39. Process validation
  40. Laminate qualification and destructive testing
  41. Curing graphics
  42. DEFECTS AND REPAIR PHILOSOPHY
    Defect classification
  43. Structural vs. non-structural defects
  44. Acceptance criteria philosophy
  45. Repair design principles
  46. Typical repair geometries
  47. Secondary bonding considerations
  48. When NOT to repair
  49. Documentation after repair
  50. CASE STUDY
    Design of a mould with an insert and split down the centre line
  51. Proposal of different support structures
  52. FINAL ASSIGNMENT
    Final Assignment
  53. COURSE MATERIALS
    Course Materials
  54. COURSE EVALUATION SURVEY
    Course Evaluation Survey
  55. SUMMARY
    Wrap-up

Hi, I’m Lucia, and I will be your instructor.

My academic background is in Naval Architecture and Marine Systems Engineering at the Polytechnic University of Cartagena.

During my industry placement, I stepped into a completely different world, Synergia Racing Group, a leading company in the manufacture of composite plugs, molds, and prototypes. What began as an internship turned into 7 years of hands-on experience in real projects, real production challenges, and real responsibility.

I began as an intern and grew into a project manager role, which I’ve held for the past 3 years. In my day-to-day work, I’m involved throughout the entire life cycle of the project from budgeting and planning to defining manufacturing procedures, 3D design, machining, and CAM programming.

I also manage materials teams and resources. As a project manager, I work closely with clients from start to finish, making sure that technical decisions, production constraints, and delivery expectations align.

Over the years, I have worked on projects such as the repair of a Spanish minesweeper, considered one of the largest glass-fiber repairs, as well as the production of high-quality, high-precision composite components for a ferry and the deck of a catamaran for one of the leading recreational catamaran builders.

My relationship with composite has never been only theoretical. I have learned them where they really matter in design decisions, manufacturing, inspection, repairs, and in all the small details that determine whether a project works well or becomes a problem later.

Many people enter this field not as composite specialists from the start. They come from naval engineering, production, design, shipyards, or technical offices, and suddenly they realized that composites are everywhere, but the knowledge is often fragmented, too academic, or hard to connect to the real world.

That is exactly why I wanted to create this course. I wanted to build the kind of course I would have loved to have at the beginning: clear, structured, technically strong, and always connected to real applications. One where you understand how composite materials behave, why they behave that way, and what that means when you have to make decisions in a professional environment.

My goal is that by the end of the course, you will not just know more about composites, but you will feel confident talking about them, evaluating options, understanding processes, and making technical decisions more clearly.