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Composite Materials 1: Manufacturing and Production

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  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

Composite materials are everywhere in modern marine engineering. They make possible lighter structures, efficient production, high-performance components, and complex repairs.

But for many professionals and students, composites still feel like a black box full of unfamiliar terminology, manufacturing choices, design constraints, and practical details that are easy to underestimate.

This course is designed to change that. Composite Materials 1 is the first level of a two-level learning path. In this first phase, you will build a practical and professional foundation in how composites are actually used in the marine industry.

We begin with the essentials: what composite materials are made of, how their components work together, how manufacturing processes affect the final result, and how to understand the terminology and data sheets used in real projects.

From there, the course moves into the decisions that really matter in practice, how to select suitable materials and processes, how composites are produced, and how to approach mold design and requirement definitions for series production. You will explore topics such as reference surfaces, demolding strategy, mold divisions, technical flanges, operational features like pressure or durability, and mold structures.

By the end of the course, the target is not simply that you know more terms. It is that you can look at composite components, a production process, a repair situation, or a technical discussion and understand what is happening, what matters, and what questions need to be asked.

If you work in design, manufacturing, inspection, or repair, or if you want to enter the field with a much stronger technical base, this course will give you the base to do that with confidence.

And because this is level one, it also prepares you for the next phase of the learning journey. So if you want composites to stop feeling abstract and start feeling usable, I invite you to join me in Composite Materials 1.