Unit of Competency Mapping – Information for Teachers/Assessors – Information for Learners

MEM26001A Mapping and Delivery Guide
Lay up composites using open moulding techniques

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency MEM26001A - Lay up composites using open moulding techniques
Description This unit of competency covers the skills and knowledge required to fabricate composites using hand lay-up and/or chopper gun and/or other open moulding techniques.
Employability Skills This unit contains employability skills.
Learning Outcomes and Application This unit covers one of the fundamental techniques for fabricating a composite product – open moulding techniques. These are the traditional methods of composite fabrication and provide great flexibility in application. Open moulding may be undertaken by an individual or a fabrication team. It may be undertaken in a workshop or factory environment or in the field and may be used to manufacture new products, prototypes and samples, or to make repairs.This unit is one of three units covering the basic composite fabrication techniques, the other two being MEM26002A Lay up composites using vacuum closed moulding techniques and MEM26003A Lay up composites using pressure closed moulding techniques, which together are intended to ensure the composite tradesperson can undertake a basic fabrication using these methods.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.
Prerequisites/co-requisites Not applicable.
Competency Field
Development and validation strategy and guide for assessors and learners Student Learning Resources Handouts
Activities 		Slides
PPT 		Assessment 1 Assessment 2 Assessment 3 Assessment 4
Elements of Competency Performance Criteria              
Element: Select process
  • Identify product requirements
  • Select open moulding technique most appropriate to product requirements
  • Identify or develop required procedures to make product using selected process
       
Element: Set up equipment/workplace
  • Select required items of equipment and ancillary equipment
  • Prepare equipment and ancillary equipment, as required
  • Assemble all equipment ready for use as required by procedure
       
Element: Prepare materials
  • Identify required reinforcing/reinforcing system
  • Determine quantity of reinforcing required
  • Prepare reinforcing as required
  • Identify required resin system
  • Identify and control hazards
  • Determine quantity of resin components required
  • Check adequate quantities are available
  • Mix resin
  • Minimise waste
  • Test resin
       
Element: Fabricate and adjust equipment and materials, as required
  • Apply gel coat, as required
  • Apply resin and reinforcing, as required
  • Ensure required resin distribution
  • Cure product
  • Remove product from mould when ready
  • Perform final verification of meeting product requirements
       
Element: Clean up and maintain equipment
  • Clean all moulding and mixing equipment
  • Undertake minor maintenance, as required
  • Prepare for next use or storage, as required
  • Inspect equipment for faults and take appropriate corrective action
  • Store equipment, as required
  • Minimise waste
  • Dispose of waste, as appropriate
  • Complete required logs and reports
       


Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Assessment for this unit of competency will occur on the job.

It is essential that the process and equipment be understood and that the importance of critical material properties, settings and readings is known. Competence must be demonstrated in the ability to recognise and analyse potential situations requiring action and then in implementing appropriate corrective action.

Consistent performance should be demonstrated. In particular look to see that:

waste is minimised

product is made efficiently and to standard

tools and equipment are appropriately maintained.

Competence must be demonstrated in the operation of all ancillary equipment to the level required for this unit of competency.

Context of and specific resources for assessment

Assessment will require the fabrication of suitable objects using open moulding techniques.

Assessment will occur over a range of situations which will include disruptions to normal, smooth operation.

Method of assessment

Typically, persons engaged in composites trade work are required to apply their skills and techniques across a range of jobs and specifications.

A single assessment event is not appropriate. On the job assessment must be included as part of the assessment process. Assessment judgements must consider evidence of the candidate's performance in a productive work environment that includes a sufficient range of appropriate tasks and materials to cover the scope of application for this unit.

Assessors should gather a range of evidence that is valid, sufficient, current and authentic. Evidence can be gathered through a variety of ways including direct observation, supervisor's reports, project work, samples and questioning. Questioning techniques should not require language, literacy and numeracy skills beyond those required in this unit of competency.

The candidate must have access to all tools, equipment, materials and documentation required. The candidate must be permitted to refer to any relevant workplace procedures, product and manufacturing specifications, codes, standards, manuals and reference materials.

Guidance information for assessment

Assessment processes and techniques must be culturally appropriate and appropriate to the language and literacy capacity of the candidate and the work being performed.

Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assignment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)

Assessment Tasks

Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.

Required skills

Required skills include:

interpreting specifications and instructions

calculation of material quantities

working safely and using personal protective equipment

removing included air

using rollers, brushes and/or chopper gun

performing vacuum leak testing

doing minor maintenance to chopper guns and/or pump systems (reciprocating airless pumps with air support)

operating and maintaining solvent cleaner (filter)

undertaking mechanically assisted movement of large parts (e.g. chain hoist)

assembling, cleaning and preparing simple and complex moulds

releasing product from simple and complex moulds (using jacks, air and water)

applying release systems (wax)

ensuring compliance to specifications

Required knowledge

Required knowledge includes:

preparation schedules, terminology and information relevant to standard work instructions

applicable codes and regulations

safe work practices and correct use of personal protective equipment

release agents surface tension

managing lay-up teams

gel coat application

reinforcement lay-up

resin types and applications

common tools/equipment and their maintenance

correct laminating techniques and finishing off (e.g. detail consolidation/rolling, check consistency and evenness of resin/glass, remove air entrapment and check with light)

managing post-cure requirements (e.g. air cure and oven cure)

production environment variables, such as effect of humidity (e.g. epoxy backbone), temperature, ultraviolet (UV) light and contamination from other processes

managing hazardous environments (e.g. styrene levels)

function of catalysts, accelerators and promoters

control of overspray

storage of moulds

housekeeping

waste disposal

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Procedures

Procedures may be written, verbal, computer-based or in some other form, and may include:

all work instructions

standard operating procedures

formulas/recipes

batch sheets

temporary instructions

any similar instructions provided for the smooth running of the plant

good operating practice as may be defined by industry codes of practice (e.g. Responsible Care) and government regulations

Open moulding techniques

Open moulding techniques may include:

hand lay-up

chopper gun

filament winding

Requirements of product

Requirements of product may be determined from various sources, including:

drawings

product specifications

customer requests

descriptions of required use of product

Equipment

Equipment includes:

moulds and mould components

resin application and dispersion tools

Preparing reinforcing

Preparing reinforcing includes:

cutting to size/shape, as required

any pre-treatment required

Logs and reports

Logs and reports may include:

paper or electronic based

verbal reports

items found which require action

Appropriate action

Appropriate action includes:

determining problems needing action

determining possible fault causes

rectifying problem using appropriate solution within area of responsibility

following through items initiated until final resolution has occurred

reporting problems outside area of responsibility to designated person

Typical problems

Typical problems may include:

contamination

air entrapment

resin rich

uneven distribution of resin

difficult mould shapes

resin curing too quickly

resin curing too slowly

failure to release

Health, safety and environment (HSE)

All operations to which this unit applies are subject to stringent HSE requirements, which may be imposed through state/territory or federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between Performance Criteria and HSE requirements, the HSE requirements take precedence

Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.

Observation Checklist

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Identify product requirements 
Select open moulding technique most appropriate to product requirements 
Identify or develop required procedures to make product using selected process 
Select required items of equipment and ancillary equipment 
Prepare equipment and ancillary equipment, as required 
Assemble all equipment ready for use as required by procedure 
Identify required reinforcing/reinforcing system 
Determine quantity of reinforcing required 
Prepare reinforcing as required 
Identify required resin system 
Identify and control hazards 
Determine quantity of resin components required 
Check adequate quantities are available 
Mix resin 
Minimise waste 
Test resin 
Apply gel coat, as required 
Apply resin and reinforcing, as required 
Ensure required resin distribution 
Cure product 
Remove product from mould when ready 
Perform final verification of meeting product requirements 
Clean all moulding and mixing equipment 
Undertake minor maintenance, as required 
Prepare for next use or storage, as required 
Inspect equipment for faults and take appropriate corrective action 
Store equipment, as required 
Minimise waste 
Dispose of waste, as appropriate 
Complete required logs and reports 

Forms

Assessment Cover Sheet

MEM26001A - Lay up composites using open moulding techniques
Assessment task 1: [title]

Student name:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

Feedback to student

 

 

 

 

 

 

 

 

Assessor name:

Signature:

Date:

Assessment Record Sheet

MEM26001A - Lay up composites using open moulding techniques

Student name:

Student ID:

Assessment task 1: [title] Result: Competent Not yet competent

(add lines for each task)

Feedback to student:

 

 

 

 

 

 

 

 

Overall assessment result: Competent Not yet competent

Assessor name:

Signature:

Date:

Student signature:

Date: