Advanced Composites

Course Description

ETI2464C — Advanced Composites is a combined lecture and laboratory course (3 credit hours / 90 contact hours) within the Engineering Technologies > Industrial Systems Technology taxonomy of Florida's Statewide Course Numbering System (SCNS). The course builds on introductory composites knowledge to develop advanced fabrication, process control, inspection, and repair competencies aligned to industry standards in aerospace, defense, marine, and advanced manufacturing sectors. Students gain hands-on experience with the processes and equipment used in high-performance composites production, including prepreg layup, autoclave and out-of-autoclave curing, vacuum infusion, nondestructive inspection (NDI), and structural repair. The course is designed with input from area manufacturers to ensure students are learning skills necessary to compete for local and regional jobs, particularly in Florida's Space Coast aerospace and defense corridor.

Learning Outcomes

Required Outcomes

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

• Identify and safely handle advanced composite materials, fibers, and resin systems, applying correct Personal Protective Equipment (PPE), contamination control, and industry safety standards.
• Perform prepreg handling and layup, including ply orientation, nesting, debulking, and laminate balance/symmetry using the warp clock convention.
• Execute vacuum bagging procedures, controlling resin distribution, bleed, and air evacuation with proper bleeder, breather, peel ply, and release film sequences.
• Apply autoclave processing parameters — including cure cycle temperature ramps, soak times, pressure application, and cooling — to produce high-quality fiber-reinforced polymer laminates.
• Perform vacuum-assisted resin transfer/infusion (VARTM/VARI) processes, placing dry fiber preforms in a mold and infusing thermoset resin under vacuum.
• Fabricate sandwich panel structures, including layup, bagging, and processing of honeycomb and foam core panels with nested fabric facesheets.
• Assess and repair composite damage by identifying delaminations, cracks, fiber fractures, and core damage using nondestructive inspection (NDI) methods such as tap testing, ultrasonic testing (A-scan/C-scan), and thermography.
• Execute structural composite repairs, including scarf and stepped repairs following Structural Repair Manual (SRM) procedures, taper ratios, and bonding techniques.
• Apply quality assurance procedures including material traceability, process verification, acceptance criteria, defect evaluation, and documentation practices in compliance with industry standards.
• Interpret and apply material and process specifications, including mix ratios, pot life management, and exothermic control for resin systems.

Optional Outcomes

Depending on institutional emphasis and available equipment, students may also:

• Demonstrate knowledge of automated tape laying (ATL) and automated fiber placement (AFP) concepts and their role in aerospace manufacturing.
• Perform or observe filament winding using wet or dry (prepreg tape) winding methods on a rotating mandrel.
• Analyze out-of-autoclave (OoA) curing techniques and compare their mechanical and quality outcomes to autoclave-cured laminates.
• Prepare for and sit for an industry certification exam such as the ACMA Certified Composites Technician – Advanced Composites (CCT-AC) or the CertTEC/SpaceTEC Fiber Composites Technician credential.
• Discuss regulatory frameworks including FAA Advisory Circulars for composite aircraft repair and MIL-SPEC/ASTM standards for composites testing.

Major Topics

Required Topics

1. Safety and Hazard Management — PPE selection and use; handling hazardous resins, hardeners, and solvents; OSHA compliance; industrial hygiene; emergency protocols; contamination control in composites environments.
2. Advanced Materials Review — Carbon fiber, aramid (Kevlar®), and S-glass fiber forms (unidirectional tape, woven fabric, braided preform); thermoset resin systems (epoxy, phenolic, cyanate ester); core materials (Nomex® honeycomb, polyurethane foam, aluminum honeycomb); comparison of advanced composites vs. fiberglass-reinforced plastics (FRP).
3. Prepreg Technology — Prepreg manufacture, material forms (UD tape, woven fabric), shelf life and out-time management, cold storage requirements, handling and cutting procedures.
4. Laminate Theory and Ply Orientation — Warp clock; ply orientation notation; symmetric and asymmetric laminates; balanced vs. unbalanced layups; fiber volume fraction; laminate design effects on stiffness and strength.
5. Vacuum Bagging Systems — Breather and bleeder selection; peel ply, release film, and caul plate application; pleating for complex geometry; vacuum leak detection; bag integrity verification; debulking procedures.
6. Autoclave Processing — Autoclave operation and safety; cure cycle parameters (temperature ramp rates, dwell/soak, pressure application, cool-down); resin flow and consolidation mechanics; tooling materials and thermal mass considerations.
7. Liquid Composite Molding — Resin Infusion Processes — Vacuum-Assisted Resin Transfer Molding (VARTM); resin transfer infusion (RTI); SCRIMP process; dry fiber preform placement; resin flow front management; port and feed line setup.
8. Sandwich Structure Fabrication — Open-face and closed-mold sandwich construction; core splicing and ramping; core plug and potting repairs; facesheet nesting techniques; processing foam and honeycomb core panels.
9. Nondestructive Inspection (NDI) — Tap testing (coin tap, instrumented tap hammer); ultrasonic inspection (A-scan, C-scan, air-coupled); visual inspection and optical methods; thermographic inspection; identification of delaminations, voids, porosity, disbonds, impact damage, and fiber fractures.
10. Damage Assessment and Composite Repair — Damage classification and allowable damage limits per SRM; material removal and scarfing; wet layup repairs; prepreg patch repairs; scarf and step-lap repair geometry; bonded vs. bolted repair selection; core and skin repair procedures; cure monitoring during repair.
11. Quality Assurance and Documentation — Material traceability and certification records; process traveler and traveler sign-off; acceptance criteria; non-conformance reporting; corrective action documentation; compliance with industry and OEM specifications.

Optional Topics

• Filament Winding — Wet winding and dry (prepreg tape) winding on a rotating mandrel; fiber tension and angle control; winding patterns; applications in pressure vessels and tubular structures.
• Automated Fabrication Methods — Automated Tape Laying (ATL) and Automated Fiber Placement (AFP) concepts; role of robotics in high-rate composite production; thermoplastic in-situ consolidation overview.
• Out-of-Autoclave (OoA) Processing — OoA prepreg systems; vacuum bag only (VBO) curing; oven cure cycles; comparison of porosity and mechanical properties vs. autoclave processing.
• Pultrusion and Press Molding Overview — Continuous pulling process for constant cross-section profiles; compression molding of Sheet Molding Compound (SMC) and Bulk Molding Compound (BMC).
• Thermoplastic Composites — Thermoplastic matrix systems (PEEK, PPS, PEKK); advantages of toughness and recyclability; consolidation and joining methods.
• Industry Standards and Regulatory Compliance — ASTM composites testing standards; CMH-17 (Composite Materials Handbook); FAA Advisory Circulars for composite repair; MIL-SPEC and DoD composites requirements.
• Certification Preparation — ACMA CCT-AC body of knowledge review; CertTEC/SpaceTEC Fiber Composites Technician exam preparation; practical competency demonstration.

Resources & Tools

• Primary Texts: Advanced Composites Study Guide (ACMA); Basic Composites Manual (ACMA); manufacturer-supplied material data sheets and processing specifications.
• Standards and References: CMH-17 (Composite Materials Handbook, formerly MIL-HDBK-17); ASTM composites testing standards (D3039, D6641, D7750); applicable FAA Advisory Circulars (e.g., AC 43.13-1B).
• Laboratory Equipment: Autoclave; vacuum pump stations and bagging consumables; prepreg refrigerator/freezer storage; resin infusion setup (VARTM); oven cure system; ultrasonic A-scan and C-scan inspection equipment; tap test instruments; infrared thermography camera; filament winding machine (where available).
• Materials: Carbon fiber and fiberglass prepreg tapes and fabrics; dry fiber reinforcements; epoxy and other thermoset resin systems; Nomex® honeycomb and polyurethane foam core; vacuum bagging consumables (peel ply, breather, bleeder, release film, vacuum bag film, sealant tape).
• Software / Digital Tools: Industry material specification databases; process traveler documentation software; ACMA online study modules and practice exams.

Career Pathways

Completion of ETI2464C prepares students for technical roles in Florida's high-demand composites and advanced manufacturing industries, including aerospace, defense, marine, automotive, and wind energy sectors. Florida's Space Coast region hosts a high concentration of defense, space, and aerospace employers actively recruiting composites-trained technicians.

• Composites Fabrication Technician — Manufactures structural composite parts using prepreg, infusion, and autoclave processes for aerospace, marine, or industrial customers.
• Composite Repair Technician — Inspects, assesses, and repairs composite structures in aviation MRO (Maintenance, Repair & Overhaul), military, or marine environments.
• Quality Control / NDI Inspector — Performs nondestructive inspection of composite parts using ultrasonic, thermographic, and tap test methods to ensure structural integrity and specification compliance.
• Advanced Manufacturing Technician — Supports automated composite manufacturing processes (AFP, ATL, filament winding) in high-rate aerospace or defense production environments.
• Engineering Technology A.S. Pathway — Credits earned in this course apply toward the Engineering Technology Associate in Science (A.S.) degree at participating Florida colleges such as EFSC.

Special Information

Certification Preparation

This course aligns with and may prepare students for nationally recognized composites industry credentials:

• ACMA Certified Composites Technician – Advanced Composites (CCT-AC): Developed by the American Composites Manufacturers Association (ACMA) for aerospace and high-performance composites manufacturing and repair professionals. Successful completion of an ACMA-reviewed advanced composites program delivering 30 or more hours of hands-on training meeting the prerequisite checklist may satisfy enrollment eligibility. Passing the proctored exam (80% or higher) earns a national credential and 3.5 CEUs.
• CertTEC / SpaceTEC Fiber Composites Technician: Industry certification aligned to Space Coast and aerospace composites manufacturing standards. EFSC's composites concentrations were developed in part utilizing SpaceTEC and CertTEC fiber composite standards and certifications.

Program Context

ETI2464C is typically offered as an advanced course within the Composite Fabrication and Testing College Credit Certificate (CCC) program. The program was designed in collaboration with area manufacturers — including aerospace, defense, and marine companies — to ensure alignment with local hiring requirements and DoD composites workforce initiatives. Students should note that composites laboratory coursework requires the use of chemicals and materials governed by safety regulations; proper PPE and adherence to lab safety protocols are mandatory throughout the course.