KP3

Practical methods of manufacturing and evaluation of chemically curable composite materials

Course objective:

After completing the training, the participant:

Has practical skills in selected techniques for manufacturing composite materials – infusion, RTM, spray-up, applying gelcoats by spray and hand methods, and processing of fiber pre-impregnates
Has practical knowledge of the construction of molds for the production of composites, the construction of individual machines and devices, as well as the basics of servicing equipment used in composites processing.
Has knowledge in the field of testing the strength parameters of resins and composite materials
Has practical knowledge of qualitative analysis of composites and resins - determining the heat deflection temperature (HDT) and basic strength parameters

Training mode

Open training

Course level

KP3

Duration

3 days, 21 hours

Prerequisites

Completion of the course KP1: Chemically and thermosetting composite materials - introduction to the subject of polymer chemistry, properties of composites and methods of their production or knowledge in this field

Training location

EMT-Systems Gliwice, Specialist Laboratories, Engineering Training Center or Customer's premises
See the training room

Training dates

year 2026

June 15-17

November 23-25

Training dates

Please contact us by phone

Agenda

day 1 8:00 a.m. - 4:00 p.m.
day 2 8:00 a.m. - 4:00 p.m.
day 3 8:00 a.m. - 4:00 p.m.

Training price

PLN 3950 (net) + 23% VAT PRICE LIST FOR ALL TRAININGS

Possibility of participating online

The price includes

Certificate of course completion in two languages – Polish and English
Training script
Writing materials, e.g. notebook, pen (for on-site training)
Comprehensive assistance from individually assigned course supervisors
Student Cards entitling you to discounts at selected partner venues in Gliwice (for stationary training)

Gourmet Catering

Participants of training sessions at our center receive unlimited access to the Cechownia Cafe coffee bar and a two-course lunch.
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Contact

tel .: (32) 411 10 00
E-MAIL: info@emt-systems.pl

Closed training

In this respect, we also organize closed training, where the dates, participation costs, location and training program are agreed individually with the client.

Certificate

After completing the training, each participant receives a bilingual, personal certificate descriptively confirming the acquired skills in accordance with the system implemented at EMT-SYSTEMS Sp. z o.o. quality management PN-EN ISO 9001:2015, supervised and certified by TUV Nord Poland.
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Accommodation

List of hotels near the training site.

Please do not hesitate to contact us

Phone: 32 4111 000

info@emt-systems.pl

in order to consult the appropriateness of the training selection

Course program

day 1	Health and safety issues when working with hazardous and harmful chemical materials. Personal protective equipment, ventilation, disposal, and first aid. Selected topics describing chemical reactions in polymerization and copolymerization processes. Chemical reaction initiators, catalysts, inhibitors, accelerators, and modifiers. Basic types and properties of raw materials that influence processing. Matrix: reactivity, viscosity, thixotropy index. Reinforcements: types and characteristics that influence the manufacturing process. Overview of processing methods for manufacturing composite materials with a polymer matrix (contact method, wet-up, spray-up, vacuum bag, infusion, LRTM, RTM, winding, pressing) Exemplary structure of a tool composite - tool gelcoat, skin-coat, non-shrink structural layer
day 2	Manufacturing composites in closed molds model construction and surface layers, processing, release agents construction principles and subsequent stages of manufacturing composite molds accessories and auxiliary materials application of release agents Applicators used in various production methods Construction and principle of operation, occupational health and safety Daily and periodic service Service work to eliminate malfunctions Optimization of applicator operation taking into account factors influencing its operation Familiarization with the construction of the applicator and partial disassembly of the systems Form preparation – surface cleaning, texture restoration, surface repairs Application of release agents Cutting reinforcement forms according to templates Application of the gelcoat layer Application of the barrier layer Preparation of construction resin Starting the applicator - initial operation steps Control activities to achieve the correct applicator parameters Starting the vacuum system and checking the readiness of the vacuum pump for operation Checking the patency of the dosing head washing system. Starting the process of dosing the resin into the mold and controlling the process parameters Stopping the process and OT applicator
day 3	Discussion block during technological breaks Demoulding the product Production of subsequent products with a modified reinforcement structure and induced defects End of applicator operation with activities necessary for long-term break Quality assessment of products, analysis of induced defects in products (determination of basic strength parameters - bending strength, tensile strength, impact strength along with heat deflection temperature - HDT, determination of glass transition temperature and crosslinking energy using a differential scanning calorimeter - DSC) Composite repairs in terms of structure and gelcoat surface (reconstruction of structural structures and grinding and polishing processes)

Laboratory equipment

The composites training rooms and laboratories are air-conditioned, large, and spacious. The student workstations are expertly equipped. Each participant has access to specialized laboratory equipment. Our training laboratories provide the opportunity work on industrial laboratory equipment and components supplied by leading technology suppliers – ZWICK/ROELL and Mettler Toledo. During the classes, participants perform numerous practical exercises using a variety of stations.

Zwick/Roell ProLine 10 kN tensile testing machine

We use the machine for functional component testing and standardized material testing. The machine is equipped with instrumentation for tensile, three-point bending, and compression testing, along with an extensometer for elongation measurement and a system table for setting up the machine and PC:

load range Fmax 10 kN,
tabletop model,
load frame, two-column H-type,
2 steel guide columns,
2 drive spindles (ball-and-roller) with preload, ensuring play-free guidance and traverse drive,
working space without construction: 1050 x 440 mm (height x width),
brushless and maintenance-free AC servo drive,
test speed in the entire load range 0 - 10 kN: 0,0005 ... 1000 mm/min,
accuracy of the set speed: 0,05% of the set value,
positioning accuracy: +/-2 μm,
innovative testControl II electronics.

Zwick/Roell HIT5P Digital Charpy Hammer

5J Pendulum Impact Tester for testing the impact strength of plastics. The testing system automatically identifies the installed pendulum, ensuring that measured values are always within the correct range and in accordance with the applicable test standard. This tester also features the world's first dual carbon fiber pendulum rod. This ensures high stiffness in the impact direction and significant mass concentration in the impact area. The electronics include a high-resolution digital encoder for accurate impact angle measurement. An RS232 interface is included for integration with laboratory management systems, along with a plug-and-play USB connection to a PC.

The laboratory is equipped with all the necessary materials to conduct top-quality practical exercises. Students have access to: resins, gelcoats/topcoats, reinforcements, initiators/hardeners, fillers, release agents, core materials, production additives, and tools. During the practical session, we examine the mechanical properties of unfilled resins and composite materials produced during the course.

Vicat & HDT ZwickRoell

ZwickRoell's HDT/Vicat Standard devices are ideal for routine supply control, quality control, and training purposes. Advantages:

simple parameterization and evaluation using testXpert III research software from ZwickRoell,
optional external cooling device available for faster initial temperature acquisition,
possible to perform tests in accordance with ISO 306, ASTM D 1525, ISO 75 and ASTM D 648.

METTLER TOLEDO DSC 3 Analyzer

Features and benefits of the METTLER TOLEDO DSC 3 analyzer

Durable MultiSTARe sensor with 56 thermocouples – ensures effective detection of very small and very large thermal effects
Durable and reliable sample feeder
Launching studies with One Click™
Easy FlexCal® calibration
Modular and ergonomic design
Wide temperature range – from -150 to 700 °C in one measurement
STARe Excellence Software

Thermal analysis, particularly dynamic scanning calorimetry (DSC), is a fundamental method for studying the thermal properties of polymeric materials. It is used as a primary research method for:

determining the melting point and polymorphic transformations of polymers
glass transition temperature
distribution of transformation temperatures and their dependence on the presence of admixtures in the polymer, solvent, degree of branching, degree of orientation, and crystalline phase content.

All of these physical transformations are accompanied by significant changes in the material's properties, which influence its processing parameters. Knowledge of these changes is essential for correctly determining all processing parameters, such as injection molding, extrusion, thermoforming, and others. Analysis allows for the determination of:

specific heat of the material
heat and temperature of melting and crystallization
heat and temperature of other phase changes
entropy of changes
heat and activation energy of chemical reactions - for curable polymers (resins)
adsorption energy etc.

It is a complementary method to other testing methods, such as viscosity measurement (melt flow index). Introducing laboratory classes using this device into the training program will significantly expand and complement knowledge of polymer materials, as modern engineering materials that are fundamental in many fields of technology. Awareness of their properties allows for the targeted and effective use of many known and new polymer materials in all areas of engineering materials application. METTLER TOLEDO DSC 3 Analyzer Training

RTM and infusion/vacuum bag form

Made of epoxy tooling systems, with a gelcoat, reinforced with glass fiber, with a surface area of up to 2 m², the mold allows for composite material production processes using infusion and vacuum bagging methods. The mold consists of two parts (upper and lower), sealed with a vacuum, equipped with nozzles for resin dispensing, and connected to a vacuum. METTLER TOLEDO DSC 3 Analyzer Training

Aluminum mold for pre-impregnation systems

A single-sided aluminum mold allows for the production of composites using fiber pre-impregnation systems cross-linked at elevated temperatures, under vacuum and simultaneous overpressure. METTLER TOLEDO DSC 3 Analyzer Training

Applicator - a modular device for RTM and spray-up with a vacuum system

Apollo Applicator

13:1 compression
Max pump capacity 2.4 GPM (9 l/min)
Supply air pressure 5-8 bar

PHOENIX 5000 gun with wet-out nozzle, gelcoat and RTM injection capability, initiator flow alarm, resin pump on pins, extended-life pump seals, OptiSlave initiator feed system, hardened stainless steel pumps, easily accessible operating parameter controls, hardener tank, solvent tank, 5m hoses, drum trolley with mast and short boom. Phoenix 5000 - Chopper

Minimum air capacity: 700 l/min at 7 bar
Chopper capacity up to 6 kg/min

Internal mixing of ingredients, pneumatically controlled trigger, lightweight and ergonomic design, solvent-resistant handle, low emission, Anti-Clog grinder, quick seal replacement. AV10 vacuum unit The unit consists of an AT10 vacuum pump, a 10-liter buffer tank, a vacuum regulator, a mobile trolley with a technical table, and a vacuum collector with outlets with quick-connect plug-in connectors.

The MA 200/1.X2.IC.A.NS Moisture Analyzer and the MA 200/1.X2.A.NS Moisture Analyzer. The MA X2 series moisture analyzers are modern devices for quickly analyzing various samples in terms of moisture, dry matter content, and other product parameters.

3COLOR LB light chamber (F, D65, TL84, UV)

3COLOR SV-300 spectrophotometer

FANGRUI NDJ-5T viscometer

Meet our company

Awards Reference Opinions

Confirmation of cooperation

Our experts

Representatives from industry and universities with extensive experience in implementation and repair work. Our trainers work daily with large enterprises, solving technical problems and assigned engineering tasks.

Gourmet Catering

Apart from the substantive aspect, it is very important to us comfort of our training participantsWe offer our students a cozy café and restaurant, a place to enjoy refreshments and relax during breaks during training. We invite you to use the coffee bar and modern massage chair!

During each training day, participants receive:

Unlimited access to the Cechownia Cafe coffee bar, serving tea and high-quality, freshly ground coffee. The bar is equipped with:
- NECTO Karisma – a professional espresso machine made in Italy.
- THERMOPLAN BW 4 – a professional Swiss-made espresso machine.
These machines are used in the best coffee shops. We serve unique coffees to suit your tastes – cappuccino, espresso, Americano, caffe latte, and Turkish coffee. Participants can also enjoy unlimited sparkling and still water, juices, and sweets.

Two-course dinner – a combination of traditional, home-cooked flavors with meals served in restaurants.

Until 16:00 PM cafe on the first floor You can also purchase fresh sandwiches, cakes, sweet and savory snacks, and cold drinks. After the training, from 16:00 p.m., we invite you to try it out. delicious dishes Cechownia Restaurant, prepared by the best chefs in Gliwice.