Composite Fundamentals

Course Description

ETI2460C — Composite Fundamentals is a combined lecture and laboratory course (denoted by the "C" suffix under Florida's Statewide Course Numbering System) within the Engineering Technologies > Industrial Systems Technology taxonomy. The course provides students with a foundational understanding of composite materials, including their constituent components, physical and mechanical properties, fabrication methods, and quality and safety considerations. Students gain both theoretical knowledge and hands-on laboratory experience working with fiber reinforcements, resin matrix systems, and core materials using industry-standard tools and techniques. This course is designed to prepare students for entry-level positions in composite manufacturing and related industries, and supports preparation for nationally recognized industry certification.

Learning Outcomes

Required Learning Outcomes

Upon successful completion of this course, students will be able to:

• Identify and describe the principal components of a composite material, including fiber reinforcements, matrix systems, and core materials.
• Explain the physical and mechanical properties of common composite materials, including strength, stiffness, and weight-to-strength ratios.
• Differentiate between thermoset and thermoplastic matrix systems and describe their respective processing requirements.
• Demonstrate safe handling, storage, and disposal of composite materials and associated chemicals in compliance with applicable OSHA and environmental regulations.
• Perform basic hand layup fabrication techniques following standard work instructions and quality criteria.
• Apply vacuum bagging principles and set up a basic vacuum bagging system.
• Read and interpret technical documentation, work instructions, and material data sheets relevant to composite fabrication.
• Identify and classify common composite defects (voids, delaminations, dry spots) and describe appropriate inspection methods.
• Describe open molding processes, including wet layup and spray-up, as foundational composite manufacturing methods.
• Apply quality control principles and conduct basic inspection of composite parts.

Optional Learning Outcomes

Depending on institutional resources and program emphasis, students may also:

• Perform vacuum infusion process (VIP) setup and fabrication.
• Describe prepreg material handling requirements and autoclave curing cycles.
• Fabricate a basic composite mold or tooling component from a pattern.
• Identify composite applications in aerospace, marine, automotive, wind energy, and sporting goods industries.
• Demonstrate basic composite repair procedures for surface and structural defects.
• Interpret and apply data from non-destructive testing (NDT) methods such as tap testing.
• Use CAD or technical drawing software to interpret composite part geometry.

Major Topics

Required Topics

1. Introduction to Composite Materials
   • History and evolution of composites in industry
   • Advantages and limitations compared to metals and other materials
   • Overview of composite applications: aerospace, marine, automotive, wind energy, construction
2. Fiber Reinforcements
   • Types: fiberglass (E-glass, S-glass), carbon fiber, aramid (Kevlar)
   • Fiber forms: woven fabrics, non-crimp fabrics, chopped strand mat, rovings
   • Mechanical properties and selection criteria
3. Matrix (Resin) Systems
   • Thermoset resins: polyester, vinyl ester, epoxy
   • Thermoplastic matrix systems (overview)
   • Catalysts, hardeners, and cure chemistry basics
   • Pot life, gel time, and cure cycle parameters
4. Core Materials
   • Foam cores (PVC, PET, balsa)
   • Honeycomb core structures
   • Sandwich panel design principles
5. Safety, Health, and Environmental Compliance
   • Hazard communication and SDS (Safety Data Sheet) interpretation
   • Personal protective equipment (PPE) selection and use
   • Ventilation requirements and chemical exposure limits
   • Waste handling and environmental regulations (OSHA standards)
6. Open Molding Processes
   • Hand layup technique: tool preparation, gelcoat application, laminate buildup
   • Spray-up process overview
   • Mold release agents and surface preparation
7. Vacuum Bagging
   • Bagging materials: peel ply, release film, breather/bleeder, bag film
   • Assembly and sealing of a vacuum bag system
   • Vacuum pump operation and leak detection
8. Quality Control and Inspection
   • Visual inspection standards and accept/reject criteria
   • Common defect types: voids, dry fiber, delamination, porosity
   • Tap testing and basic non-destructive evaluation
   • Documentation and traceability in composite manufacturing
9. Technical Documentation
   • Reading and interpreting work instructions and engineering drawings
   • Material data sheets and cure schedules
   • Lab reporting and quality records

Optional Topics

1. Vacuum Infusion Process (VIP)
   • Principles of resin infusion and flow media
   • VIP setup, infusion execution, and troubleshooting
2. Introduction to Composite Tooling
   • Pattern and mold construction concepts
   • Positive and negative mold geometries
   • Mold maintenance and lifecycle
3. Prepreg and Autoclave Processing (Overview)
   • Prepreg material handling and cold storage requirements
   • Autoclave cure cycle parameters
4. Composite Repair Fundamentals
   • Types of damage and repair classification
   • Scarfing and stepped repair concepts
5. Advanced Fiber Architectures
   • Unidirectional (UD) laminates and orientation effects
   • Filament winding and pultrusion overview

Resources & Tools

• Textbook: Basic Composites Manual — American Composites Manufacturers Association (ACMA); available in print and digital editions
• Reference: ACMA Open Molding Study Guide and Vacuum Infusion Process (VIP) Study Guide (ACMA Education Hub)
• Online Platform: ACMA Education Hub (acmanet.org) — self-paced study materials aligned to CCT certification content
• Open Courseware: NSC Composites Technology Pathway (Carnegie Mellon OLI) — open and free hybrid course modules covering materials, safety, and fabrication processes
• Lab Equipment: Vacuum pump and bagging system, laminating tools (rollers, brushes, squeegees), mold release and surface prep supplies, digital scale for resin metering, PPE station
• Materials: Fiberglass fabric (woven and mat), carbon fiber (optional), polyester and/or epoxy resin systems, core materials (foam, balsa), peel ply, breather, vacuum bag film
• Standards & References: OSHA 29 CFR 1910 (General Industry), applicable SDS documents, ASTM composite test method standards

Career Pathways

Completion of ETI2460C supports entry into a range of technical careers in advanced manufacturing and composites-intensive industries. Florida's aerospace, marine, defense, and renewable energy sectors are major employers of composites technicians.

• Composites Fabricator / Laminator — produces composite parts using hand layup, vacuum bagging, and infusion processes in production environments
• Composite Repair Technician — performs structural and cosmetic repair of composite components in aerospace, marine, and automotive settings
• Quality Control / Inspection Technician — inspects composite parts for defects and ensures compliance with engineering specifications
• Manufacturing Technician (Aerospace & Defense) — supports production of composite airframe structures, rotor blades, and secondary structures
• Wind Energy Technician — fabricates or maintains composite wind turbine blades and nacelle components
• Marine Composite Fabricator — builds or repairs fiberglass and carbon fiber marine vessels and components
• Tooling Technician — constructs and maintains composite molds and tooling used in production

This course may be embedded in, or articulate toward, an A.S. in Engineering Technology or a Composite Fabrication and Testing College Credit Certificate (CCC) at participating Florida colleges.

Special Information

Certification Preparation

ETI2460C is designed to prepare students for the American Composites Manufacturers Association (ACMA) Certified Composites Technician (CCT) credential, which is the industry's nationally recognized certification for composites manufacturing professionals. The CCT program includes the following specialization tracks most relevant to this course:

• CCT – Basic Composites: Covers composite history, fiber reinforcements, matrix systems, and basic fabrication processes. Assessment is a 100-question proctored online exam; a score of 80% or higher is required to pass.
• CCT – Open Molding (CCT-OM): Focuses on hand layup and spray-up fabrication processes and quality standards.
• CCT – Vacuum Infusion Process (CCT-VIP): Covers closed-mold infusion techniques (may require additional coursework or lab hours beyond this course).

Students are encouraged to use the ACMA Education Hub study materials, which are aligned directly to CCT exam content, as a supplement to course instruction. Instructors may coordinate on-site proctored CCT exams upon course completion where institutional agreements exist.

Safety Note

Due to the use of resins, solvents, and fibrous materials in the laboratory component of this course, students are required to wear appropriate PPE at all times during lab sessions and to complete a laboratory safety orientation before participating in any hands-on activities.