UNIT 47: COMPOSITES MANUFACTURE AND REPAIR PROCESSES
Unit 47: Composites Manufacture and Repair
Processes
Level: 3
Unit type: Internal
Guided learning hours: 60
Unit in brief
Learners explore the wet and dry lay-up processes used to manufacture and repair fibre-based
composite materials.
Unit introduction
We may not realise it but most of us come into contact with products or components made from
fibre-reinforced polymer (FRP) composite materials on a daily basis. Whether it is the diving board
at your local pool or the aeroplane flying overhead, their use is commonplace and becoming more
prevalent. Glass fibre-reinforced polymers (GFRP) have all but replaced conventional materials,
such as wood in the construction of speedboat hulls as they reduce manufacturing complexity,
and carbon fibre-reinforced polymers (CFRP) have replaced aluminium alloy in motorsport
structural components by providing the required tensile strength and stiffness and a considerable
weight saving.
In this unit, you will explore the nature of FRP composites and their applications across a number
of engineering sectors. You will also use different techniques to manufacture components from FRP
composites and repair components that have sustained damage in service.
As an engineer it is important to understand the properties and applications of FRP composites
and the techniques that can be used to repair them. This unit helps to prepare you for employment,
for example as a manufacturing or maintenance technician, for an apprenticeship and for entry to
higher education to study engineering.
Learning aims
In this unit you will:
A Examine the characteristics and applications of fibre-reinforced polymer composites
that are widely used in industry
B Investigate the processes used to manufacture and repair fibre-reinforced polymer
composites
C Carry out processes to manufacture and repair fibre-reinforced polymer composite
components.
Pearson BTEC Level 3 National Extended Diplomas in Engineering – 557
Specification – Issue 7 – September 2019 © Pearson Education Limited 2019
, UNIT 47: COMPOSITES MANUFACTURE AND REPAIR PROCESSES
Summary of unit
Learning aim Key content areas Recommended
assessment approach
A Examine the characteristics A1 Characteristics of fibre An illustrated written report
and applications of materials covering the characteristics
fibre-reinforced polymer A2 Characteristics of polymer and applications of FRP
composites that are widely resin matrix materials composites. Where possible
used in industry A3 Structure and mechanical case study material should be
properties of FRP used to illustrate the
composites applications of fibre-based
composites where they have
A4 Applications of FRP
replaced traditional materials.
composites
B Investigate the processes B1 Safe working practices for
used to manufacture and FRP composites A written report to
B2 Characteristics of wet and evaluate wet and dry lay-up
repair fibre-reinforced
dry lay-up manufacturing manufacturing processes and
polymer composites
processes those used to repair damaged
components.
B3 Repairing FRP composites
C Carry out processes to C1 Applying wet and dry lay- A written report, including
manufacture and repair up manufacturing annotated sketches and
fibre-reinforced polymer processes photographs, showing
composite components C2 Applying FRP composite learners manufacturing an FRP
repair processes composite component using
wet or dry lay-up processes
and applying appropriate
repair processes to worn
or damaged fibre-based
composite components.
Learners’ evidence should be
supported with observation
records.
558 Pearson BTEC Level 3 National Extended Diplomas in Engineering –
Specification – Issue 7 – September 2019 © Pearson Education Limited 2019
Unit 47: Composites Manufacture and Repair
Processes
Level: 3
Unit type: Internal
Guided learning hours: 60
Unit in brief
Learners explore the wet and dry lay-up processes used to manufacture and repair fibre-based
composite materials.
Unit introduction
We may not realise it but most of us come into contact with products or components made from
fibre-reinforced polymer (FRP) composite materials on a daily basis. Whether it is the diving board
at your local pool or the aeroplane flying overhead, their use is commonplace and becoming more
prevalent. Glass fibre-reinforced polymers (GFRP) have all but replaced conventional materials,
such as wood in the construction of speedboat hulls as they reduce manufacturing complexity,
and carbon fibre-reinforced polymers (CFRP) have replaced aluminium alloy in motorsport
structural components by providing the required tensile strength and stiffness and a considerable
weight saving.
In this unit, you will explore the nature of FRP composites and their applications across a number
of engineering sectors. You will also use different techniques to manufacture components from FRP
composites and repair components that have sustained damage in service.
As an engineer it is important to understand the properties and applications of FRP composites
and the techniques that can be used to repair them. This unit helps to prepare you for employment,
for example as a manufacturing or maintenance technician, for an apprenticeship and for entry to
higher education to study engineering.
Learning aims
In this unit you will:
A Examine the characteristics and applications of fibre-reinforced polymer composites
that are widely used in industry
B Investigate the processes used to manufacture and repair fibre-reinforced polymer
composites
C Carry out processes to manufacture and repair fibre-reinforced polymer composite
components.
Pearson BTEC Level 3 National Extended Diplomas in Engineering – 557
Specification – Issue 7 – September 2019 © Pearson Education Limited 2019
, UNIT 47: COMPOSITES MANUFACTURE AND REPAIR PROCESSES
Summary of unit
Learning aim Key content areas Recommended
assessment approach
A Examine the characteristics A1 Characteristics of fibre An illustrated written report
and applications of materials covering the characteristics
fibre-reinforced polymer A2 Characteristics of polymer and applications of FRP
composites that are widely resin matrix materials composites. Where possible
used in industry A3 Structure and mechanical case study material should be
properties of FRP used to illustrate the
composites applications of fibre-based
composites where they have
A4 Applications of FRP
replaced traditional materials.
composites
B Investigate the processes B1 Safe working practices for
used to manufacture and FRP composites A written report to
B2 Characteristics of wet and evaluate wet and dry lay-up
repair fibre-reinforced
dry lay-up manufacturing manufacturing processes and
polymer composites
processes those used to repair damaged
components.
B3 Repairing FRP composites
C Carry out processes to C1 Applying wet and dry lay- A written report, including
manufacture and repair up manufacturing annotated sketches and
fibre-reinforced polymer processes photographs, showing
composite components C2 Applying FRP composite learners manufacturing an FRP
repair processes composite component using
wet or dry lay-up processes
and applying appropriate
repair processes to worn
or damaged fibre-based
composite components.
Learners’ evidence should be
supported with observation
records.
558 Pearson BTEC Level 3 National Extended Diplomas in Engineering –
Specification – Issue 7 – September 2019 © Pearson Education Limited 2019
