Composite Tooling Fabrication Part 1

This is our basic Part 1 composite tooling fabrication course designed for technical departments that want to learn how to fabricate a tool or mould from a Master Model using the latest materials and techniques.
Working with Low-Temperature Molding (LTM) glass fibre prepreg or carbon fibre prepreg material, which needs to be post-cured.
 

The following definitions of minimum teaching levels are derived from Title 14 Code of Federal Regulations, Part 147, and may be exceeded.

Level 1
Level 1 requires knowledge of general principles and includes instruction through lectures, demonstrations, and discussions, but does not involve practical application or the development of manipulative skills. This teaching level generally refers to classroom discussion and does not require a practical application. Teaching aids or instructional equipment may include charts, books, diagrams, or other visual teaching aids. If a training organization chooses to teach Level 1 courses incorporating actual components, the components do not have to be operational. 

Level 2
Level 2 requires knowledge of general principles and includes instruction through lectures, demonstrations, discussions, and limited practical application; however, it does not involve the development of sufficient manipulative skills to perform basic operations. This teaching level requires some hands-on, manipulative skills and their accompanying actual or simulated components/equipment, but it can still be taught primarily in a classroom environment.

Level 3
Level 3 requires knowledge of general principles and includes instruction through lectures, demonstrations, discussions, and a high degree of practical application to develop sufficient manipulative skills to accomplish a return to service (regular operation). This teaching level requires hands-on skills and sufficient, appropriate instructional aides to train students to develop manipulative skills sufficient to simulate the return to service of mechanical skills. At this level, the teaching aids must be similar to or be the actual equipment items on which the student is expected to develop required skill levels. A Level 3 subject cannot be taught solely through a lecture in the classroom; the appropriate training aids and hands-on experience must also be utilized.


Day(-s): 5 / Tech code: TECH-170

Date Location Price Subscribe
2026-04-20

NL GTM

3495 Subscribe here
2026-05-11

GTM NL

3495 Subscribe here

This includes designers, engineers, fabricators, technicians, and those working with prepreg  fiberglass  or carbon fiber, using LTM  tooling, curing at low temperatures
Advised prerequisite for our EFC Course,  EASA /FAA approved PART 1  TECH-101 
If not, but not mandatory, a 2- to 5-year history of experience with advanced composite materials, layup, and repair is recommended for this course or an equivalent level.

If you are
unsure about your level, please contact us to have your equivalent level of training assessed. This includes designers, engineers, fabricators, technicians, and those working with prepreg fiberglass cloth or carbon fiber cloth, using an LTM tooling prepreg


Personnel of technical departments, tool designers, tooling engineers, tool fabricators, composite repair technicians, and others who want to learn about tool design and building carbon and glass fiber moulds to achieve in-depth skills in Composite Tooling fabrication
Participants will use carbon fiber or glass fiber Low-Temperature Moulding (LTM) composite pre-preg materials, carbon fiber cloth with a tooling resin to cure at room temperature able to post-cure

 


Minimum required 2 and maximum 8 per course*.

* Courses will be confirmed as running by EFC as soon as sufficient applications are received!

At the end of the course, the participant:

  • Has a better knowledge of composite design and tool design, and fabrication of glass or carbon fiber LTM prepreg tooling
  • Knows the carbon fiber pre-preg part tooling routes to follow and can interpret (CTE) Coefficient of Thermal Expansion rules 
  • Knows and has the skills to apply  surface preparation of a master model
  • Can read and understand Tooling Ply-Lay-Up drawings and tool design tolerances
  • Can apply wax sheets
  • Is familiar with the tool index and trim fixtures
  • Knows how to apply mould release agents on carbon fiber materials
  • Can incorporate Leak frames with  LTM prepreg fiber material
  • Can fabricate and apply Tool backup structure stiffeners, fences, return flanges, egg crate, or omega stiffeners design
  • Knows how to use and  wax sheets for  offsets and wax radius curves
  • Can apply vacuum bags for tooling with pleats
  • Will have advanced knowledge and skills to apply to Low-Temperature Moulding (LTM) Carbon  Prepreg materials
  • Knows about LTM Curing and Post-Curing glass carbon fiber 2x2 Twill materials made for composite tools/moulds.
  • Will be able to perform some composite  trimming of carbon fiber edges with an air router
  • Knows how to perform tool maintenance on glass or carbon fiber and repairs on the tool surface.

 

(Level 2,3) is familiar with and knows about:

  • Health and Safety (SMDS)
  • Pre-preg part tooling routes and family
  • Tool codes/acronyms and designations
  • Tool polyurethane foam block
  • Toolmaking from existing parts
  • Tooling backup structure fabricated by infusion.
  • The tool support the structure and integrated stiffener design
  • Tool index features
  • Mould tool joggle lay-up
  • Attachment of wet Lay-up cleats
  • Inserting permanent vacuum points and air transportation venting lines
  • Familiar with the coefficient of Thermal Expansion (CTE)
  • Tool spring back correction on positive and negative master models, and adjustable spring back correction
  • Use of pre-cured tool inserts
  • Application of de-bulks
  • Application of tool leak prevention frames in edges/flanges
  • Cure cycle temperatures versus Tool life cycle
  • One-off tooling and prototyping
  • Application of Quick Repair Tooling
  • Tooling vacuum bag systems
  • Tooling materials and low and high-temperature cure cycles, and out-of-life-time
  • Tool exothermic reactions
  • Reusable vacuum bags for tooling
  • Tool surface pinhole filling
  • Laminate wrinkling and bridging
  • Application of tool sealers and release agents
  • Tool Fault Finding Checklist
  • Tool dry run finding hot and cold zones by TC placement
  • Tool numbering and  placards, and Tooling logbook information
  • Tool maintenance and tooling repair

(Level 2,3)

The participant will be able to:

  • To apply the Surface Preparation of master models
  • Cut square tiles of the required size with Aluminium templates.
  • Extending the existing glass or carbon fibre flanges of a model 
  • Apply Fences for return flanges  
  • Apply wax sheets and wax radii
  • Keep a record of tooling prepreg Out-time on out-time sheets and layup travellers
  • Apply tool index features
  • Apply support structure, Omega-shaped stiffeners, and or egg crate design
  • Apply leak prevention frames
  • Apply glass fibre strands in each ply
  • Fabricate fibreglass or carbon LTM tooling material
  • Apply debulks
  • Apply vacuum material without bridging of applied vacuum materials
  • Apply  vacuum materials for Autoclave  and  Non-autoclave cures and pleats for vacuum ports
  • Fabricate a tool trim fixture with foam core material and dry fibres by wet lay-up
  • Be able to program and monitor oven parameters during curing to prevent exothermic reactions.
  • Perform a heat serve before curing the actual cure
  • After the post-cure, they have to perform a leak Check using the water infusion method and apply leak prevention methods when necessary 
(Ref: SAE-AIR4938 Original paragraph. numbering)
5. EXAMINATIONS 
  • EFC as Training Providers will be required to monitor the student/participant's performance throughout the program. 
  • Students will be administered a practical certification assessment following laboratory classes. It is recommended to use a checklist to evaluate the functional certification assessment.
  • The written certification examination and practical certification assessment will cover the principles of the applicable curriculum and consist of:
  • The written examination for certification shall contain approximately. Eight (8) multiple-choice questions per course day with a maximum of fifty (50)* per exam.
  • The number depends on the use of three or four alternative answers per question
  • The examination shall contain questions from each of the Topics listed in the outline for each Part.
  • The examination will be a closed-book examination.
  • Successful completion is 75% correct answers.
  • Reexamination: If the student fails the written examination, they may request to retake the written test. 
  • ​The written examination must not contain more than 20% of the questions that were on the failed examination.
Practical certification assessment: 
The student must demonstrate to the approved training provider that they can perform the necessary tasks required to complete the applicable repairs. 
  • All grades will be recorded in the participant's individual training records and kept on file at EFC for an unlimited period (compliant with EASA Commission Regulation (EU) No 1321/2014 and GDPR rules).
  • A certificate of accomplishment is handed out to each participant.
  • Assessment activities are built into our courses to give feedback on the achievement and personal potential, and a record is kept in their personal logbook.
  • The outcome of the participant's Examination, assessment document, and logbook per student will be digitally sent to you or your company's responsible manager or HR department.
6. CERTIFICATION
Part 1 certification shall  consist of documentation of successful completion of: 
  • A repair training program, the required exams, and assessments based on this AIR curriculum, and conducted by a training provider, follow the AIR guidance.
  • OR successful completion of the required exams and assessments based on this AIR curriculum without completion of a training program. Attempting the exam and assessment without prior training is not recommended for personnel without experience in composite repair.
EFC SAE-AIR 4938C Part 2, Part 3, and Part 4 certification shall consist of completing a repair training program, the required exams, and assessments based on this AIR curriculum and conducted by a training provider following the guidance outlined in this AIR. 
 
CURRENCY AND RECURRENT TRAINING RECOMMENDATIONS
Currency: Personnel should demonstrate continued competence every 3 years by performing a repair or by completing a practical assessment under the direct supervision of an examiner authorized and designated by the organization or by having participated in or performed at least six repairs applicable to the specific certification (i.e., Part 1, Part 2, etc.) in the 3-year period.
Please contact us for information on our currency or recurrent training program, EFC TECH-022.
Recurrent Training: A training program should include provisions for recurrent training to continually update personnel on technology, materials, and other changes related to composite and/or metal-bond maintenance and repair. The organization and the individual should maintain records of recurrent training.
 
7. RECORDS
The certifying agency or its designee shall maintain certification records for as long as certification is in effect and a minimum of 5 years after the certificate has expired. Such records shall be available for audit by authorized personnel. 
The training agency shall maintain training records for a minimum of 5 years. Such records shall be available for audit by authorized personnel. 
EFC, as an approved training provider, complies with the European AVG/GDPR rules, effective as of May 25, 2018, concerning the storage of training records and private information of participants who attend our courses. Students and participants sign their first-day Administration form to approve the storage of their training records.
This course can also be held at our facility in Leipzig Germany at the facilities of our partner HEICO. If you have a need for this, please contact our purchasing manager Rolf Hovener via his page. For your company to benefit, this course can be held 'On-Site' at your facility under certain conditions.
Click on this link to the Onsite information webpage!

Courses as noted on our course schedule page can be run on request to meet your required start and end date. All listed course prices are Excl VAT. (Dutch VAT is 21%). EFC complies with Dutch tax laws. On request, companies can be sent an invoice instead of paying direct On-line with PayPal, IDEAL or credit card.

Payment is securely arranged via Mollie.nl . More information can be found on the website of Mollie.




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