Training VRTM Mould Building Training

VRTM Mould Building

Composite Integration provides practical technical support and consultancy in all aspects of ‘closed-mould’ processing.
Training in mould construction is available in the form of structured courses and/or practical on-site assistance.

The standard Training Course consists of a mixture of theoretical and practical work, and is designed to give a practical basis for mould builders, an understanding of the design requirements for the composite component designer, as well as detailed knowledge of the moulding process in general.

The course covers the following areas:

  • Component design for process. An overview of various moulding projects with case studies to highlight particular aspects of the process.
  • Pattern design and preparation. Materials for pattern construction, supporting structure, flange design, surface treatment, release agents and dimensional tolerances.
  • Mould construction. A complete and practical breakdown of each stage of the mould building process.
  • Mould building materials. Specification of tooling resins, gelcoats, core materials etc. Epoxy, vinyl ester, polyester, Low-profile and hybrid tooling systems.
  • Calibration Wax. Building an accurate moulding cavity between the mould surfaces using sheet wax. Alternative calibration materials. Surface treatments. Release agents.
  • Vacuum. The use of vacuum to maintain accuracy during the mould building stages. Vacuum equipment and its application.
  • Mould sealing systems. The specification and application of various mould sealing systems. Alternative seal types (inflatable seals etc). Flange design to accommodate different seal types.
  • Injection / vent insert application. Optimum insert positioning for effective fill and minimum wastage. Types of injection port and injection valves.
  • Moulded inserts. Threaded inclusions within the laminate. Conventional threaded insert carriers, magnetic insert carriers. Moulding around cores. Specifying core materials- wood, foam, metal etc.
  • Injection materials. Specification of injection resins, accelerator and catalyst systems. Injection resins designed for optimum surface finish, fibre types including surface veils. The use of woven and non-woven directional fibres.
  • Release agents. Specification and use of release agents for different resin systems. Internal release agents.
  • Injection strategies. Mould lay-out and design for optimum performance. Injection and vent strategies for complex mould geometry.
  • Process Vacuum. The use of vacuum for injection and clamping purposes. Requirements for different vacuum levels and methods of achieving this.
  • Injection equipment. A comprehensive overview of different types of injection equipment. The application and use of injection equipment. The importance of pressure / flow control. Trouble shooting and machine maintenance.
  • A full training manual, video and all relevant supporting information covering any of the materials/components used is provided.

The following video shows an overview of the construction of a typical VRTM mould.
The full version of this video is provided as part of the standard mould-building training course.

Typical Training Agenda
Day 1
9.00: Welcome
  • Introduction and safety rules
  • Introduction to Composite Integration Ltd
  • Introduction to VRTM closed-moulding
11.00 Coffee
  • Discussion of tool building materials and pattern techniques
  • 1st half tool manufacture
  • Practical workshop session: Practical injection Demonstration
13.00 – 14.00 Lunch
  • 1st half tool manufacture (continued)
  • Using calibration wax to form the product thickness
15.30 Coffee
  • Practical workshop session (Waxing and laminate techniques)
  • Injection trials
  • Questions
  • 17.00 Finish
    Day 2
    8.30: Welcome
    • Practical workshop session- Complete waxing and position mould inserts
    • Building the second tool half
    • Mould separation, cleaning and release
    • Practical workshop session – Various injection demos
    11.00 Coffee
    • Tool commissioning, Inserts, cores and materials
    13.00-14.00 Lunch
    • Tool design and injection strategies
    • Materials for RTM
    • Practical workshop session – Various injection demos
    • Discussion of injection and vacuum equipment
    • Questions
    17.00 Finish
    Day 3
    8.30: Welcome
    • Practical workshop session- Infusion with Ciject equipment
    • General discussion and final Q&A session.
    • Presentation of certificates
    12.00 Finish

    Training Courses are run regularly throughout the year and are often arranged to suit specific customers requirements.
    Please contact Composite Integration to discuss dates.