11

Composite Technician Program

for Technical Colleges

Dave Crockett and Tim Wright

August 2016

Contact Email: dcrockett@osprey-tech.com

Phone: 480-755-0445

22

Advanced Composite Structures

Composite structures are experiencing rapid growth in all

industries: Auto, Marine, Aerospace, Military, Aviation,

Recreation, Civil, Chemical Plants, Wind, and more

33

Growth in Composite Usage

Composite use is predicted at a 7%

increase overall for all industries

Aviation will see most significant

increase. Boeing’s all composite

787 heralds in new era in aviation.

44

Overview of Advanced Composite

Technology Needs in Industry

Manufacturing

High Volume

* Limited Skill: Specialty training for use of limited automated equipment

Low Volume

* Highly skilled: Capable of fabrication in numerous hand and automated processes and assembly, read engineering drawings

Inspection/QA

Highly Skilled

* NDI certification* Composite technician

Skilled

* Composite technician with knowledge of NDI methods

Repair

Highly Skilled

* Certification for Aviation/Aero

Skilled

* Certification for marine, wind turbine industrial, etc.

55

Demand for Composite

Technicians

Growing use of composites is driving demand for technicians

trained in fabrication and repair of composite structures

Fabrication processes range from hand layups to automated

processes such as filament winding and fiber placement

─ New manufacturing processes continuing to evolve

Machining of composites is different than metals requiring new

skill sets

Repair of composite structures in aviation, aerospace, marine,

wind energy, and industrial tanks and piping systems require

trained technicians

─ Aviation is most stringent with repair

─ With growing number of composite aircraft there is a greater need for

composite repair technicians (FAA sighted lack of trained composite

technicians as major concern for continued flight safety)

66

Career Opportunities

Careers are available in all industries (automotive, aviation,

aerospace, marine, recreation, wind energy, industrial plants,

and more)

Opportunities in manufacturing range from composite part

fabrication, production line repairs, testing (structural and NDI),

operation of automated equipment, machining, and quality

assurance

Repair of composite structures requires highly skilled

technicians. This is especially true for repair of aircraft

structures. However, repair technicians are used extensively in

wind energy, industrial plants and fluid piping systems, civil

structures, military/aerospace, and marine. Opportunities

include:

─ Damage assessment inspectors

─ Hand and automated repair technicians

─ QA and inspection

77

Employment Outlook for

Composite Technicians

United States Department of Labor indicates a projected growth

of nearly 10% by 2018 in the aircraft and transportation-

manufacturing sector

─ Ref: TARRANT COUNTY COLLEGE DISTRICT Northwest Campus New

Certificate Program Certificate of Completion In Advanced Composites

Technology Implementation Fall Semester 2012

Average salary for a composite repair technician in the US is

$48,220

─ Ref: (http://www.salaryexpert.com/salarysurveydata/job=aircraft-composite-

technician/salary)

88

Current Certification in Industry

American Composites Manufacturing Association (ACMA) has

instituted certifications for different manufacturing processes

Aviation repair certification currently does not exist, however,

several organizations are pursuing

─ Society of Automotive Engineers (SAE) through their Commercial

Aircraft Composite Repair Committee (CACRC) is pursuing FAA

recognized certification: ARP-6262: Basic Composite Repair Technician Certification Standard (little content

to this document)

AIR-4938: Composite and Bonded Structure Technician/Specialist Training

Document (currently only 25% complete)

─ National Center for Aerospace & Transportation Technologies

(NCATT) drafted their standard: Advanced Composite Technology

Standard, Fundamentals for Repair Technicians

A few colleges throughout the country do offer a variety of 2

year degrees, technical diplomas, or their own certifications

99

Training to Meet Demand

Composite technician training is in its infancy

─ Historically companies trained on-sight for specific tasks

Limited scope in training, low pay, and high turnover

Some private training institutes such as Abaris

─ Expensive

With growing demand, technical colleges are now developing

their own composite programs

─ However limited curriculum database and poor understanding of

industry needs results in development challenges

We (Osprey Technologies) have developed a composite

technology program that can be tailored to suit the institutes’

and student’s needs from 1-semester certificates up to 2-year

associate degrees

We offer consulting to help identify program needs and

requirements and then assist in putting that program into place

1010

Osprey’s Composite Technician

Program Overview and Integration

Program will cover all aspects of technical

competencies for composite fabrication and repair

─ Competencies are defined for all courses

Includes industrial safety training with emphasis on

handling hazardous materials

Easily tailored to meet specific needs of local

industry

Tailored to integrate into schools’ current curriculum

Define layout of lab with needed supplies

─ Comprehensive list of suppliers and costs

Provide instruction to get program going; assist in

instructor selection and training

Curriculum comes complete with lectures and test

database questions

1111

Program Course Top Level Chart

Approximately 30% classwork with 70% lab work

Composite Tech Program

Composite Technology Specific

FabricationMath

Communication

etc.

Common Industrial

General Studies

Repair

Certificated Aviation

Repair

(bolted, bonded)

Marine Repair

NDI

QA/QC

Haz Mat Safety

Industrial Safety

Eng Drawings

Tooling

Machining

Hand Layup

Infusions

Automated processes

1212

Additional Program Benefits

This composite technology program also produces additional

benefits resulting in stronger ties with other institutions,

businesses, and community

Following are examples from the program at WITC in Superior, WI

─ Industry partnerships in solving manufacturing problems

Work with Kestrel to resolve tooling and layup issues

─ University ties in research

Partnership with University of Wisconsin-Stout in 3D print tooling for

composites and iso-grid structures

─ Specialized training for local industry

Cirrus Aircraft in composite repair for production line

─ Adult education for boat building or repair (as an example)

─ Introductory class for high school students – ability to obtain

college credits

─ Donation of materials from industry

Program provides foundation on which to build an educational

technology curriculum for a growing high tech industry

1313

Supplies and Facilities

Facility requirements will vary with scope of program and

number of students

─ Example WITC with full program of 16 students has a 2200 ft² lab and class

room

Supplies fall into initial non-recurring (NRE) and annual

recurring (RE) costs and depend on scope of program; following

table provides approximate cost range to set up and operate for

20 students

Range NRE Annual RE

Basic Aviation Repair Certification TBD TBD

Full Fabrication and Repair Program TBD TBD

1414

Request for Proposal (RFP)

Proposal would include costing/schedule for defining

program ─ Baseline and scope

─ BOM for NRE and annual RE costs

─ Facilities/lab layout for existing space

Options to include in response to RFP─ Research/evaluation for program viability

─ Demographics of institute with included industry

─ Potential for growth and support of industry

─ Provide recommendation for program scope with included potential

growth

─ Aid in instructor selection and training as required

1515

Backup Slides

1616

Program History

Wisconsin Indianhead Technology College (WITC)

─ Full program focused on manufacturing and repair for all

industries

─ Noted ties to local businesses for manufacturing resolution

─ Research in 3D print tooling and iso-grid structures with

University of Wisconsin-Stout

Northland Community College

─ Aviation repair course per CFR Part 147

1717

Termination of Program at WITC

WITC’s composite program had a tumultuous history,

as well as the decision process to terminate it.

Following is a brief summary of the facts in

chronological order:

Year 2013:

─ Kestrel Aircraft moves aircraft manufacturing to Superior, WI.

Works land deal with Douglas County. Governor Walker

promises seed money to get the manufacturing facilities in

place.

─ A 2-year $650k grant is awarded to WITC to develop a

composite program to support Kestrel. Grant requires WITC

to produce 2 year associate degree program.

─ WITC quickly puts program in place with one instructor.

News that Kestrel will be building aircraft results in full

enrollment into program.

1818

Termination of Program at WITC

(continued)

School year 2013-2014:

─ Second instructor is hired. Full curriculum is developed.

Additional capital equipment is procured: filament winding

machine, 3-axis CNC table mill, and RTM machine.

─ Formed program advisory committee. All members are

business leaders involved in the composite industry.

─ Program develops ties to other universities and companies

for manufacturing research and development. Examples

include:

Winona State and University of Delaware for proposal for national

manufacturing center of excellence

Kestrel Aircraft for manufacturing tooling development

─ WITC president who put program in place moves to new

position as president of University of Wisconsin-Stout. New

president begins at WITC.

─ Campus administrator that oversaw program startup at

Superior campus retires. New administrator takes over.

1919

Termination of Program at WITC

(continued)

School year 2013-2014 (continued):

─ End of school year: rumors surface that Governor

Walker/Wisconsin was failing to provide seed money to

Kestrel. No students register for next school year.

─ Instructors, technical dean, and advisory committee meet

and decision is made to change program from only aviation

focused to supporting the entire composite industry. This is

to include issuance of certifications, technical diplomas, as

well as associates degrees (which was mandated by grant).

2020

Termination of Program at WITC

(continued) School year 2014-2015:

─ New program is developed with approval process going into the

state. Program is approved and is planned to start in the 2015-

2016 school year when the grant restrictions are lifted.

─ Program provides composite training to local high schools

─ One instructor retires; only one needed for current enrollment

─ Students take internships at Cirrus and AAR. All are offered full-

time positions within weeks of starting. Several opt-out of

program to begin their composite careers. Demand for students

is realized. AAR donates $4k to marketing.

─ Over the objections from deans, instructors, and advisory

committee, and while receiving grant money to develop the

program, the new campus administrator terminates enrollment.

When grant committee finds out, they pull $50k from the college

and require enrollment be reinstated. Enrollment decline is

immediately realized, and revenue is lost.

─ 100% of first graduating class obtain positions at AAR and Cirrus

2121

Termination of Program at WITC

(continued)

Summer of 2015:

─ Technical deans from all other Wisconsin technical colleges

meet at WITC to see the composite program

─ It is noted that WITC is the only college in the state offering

training in composite technology

─ Deans herald it as a “center of excellence” for the state and

an “incubator for composite technology programs” for other

colleges in the state

─ Enrollment grows for coming school year; includes students

from southern Wisconsin

─ Evidence of growing recognition demonstrated

2222

Termination of Program at WITC

(continued)

School year 2015-2016:

─ 8 weeks into school year, new campus administrator

terminates program without informing instructor, dean, or

advisory committee. Sights lack of enrollment, funding, and

cost of carrying 2 instructors. Objections are raised to the

President. School’s VP of Finance updates costs to show

there is only 1 instructor as other retired at the end of 2014.

Updated cost demonstrates program is competitive with other

college programs.

─ New president states there is little need for the program since

Kestrel no longer intends to build aircraft in Superior, and

having budget issues; final decision given to campus

administrator who terminates with no further enrollment.

─ Advisory committee supports moving program to another

college; several companies approach Lake Superior College

(LSC) in Duluth to take program. LSC is investigating.

2323

Testimonies to Program

2424

Other Testimony References

WITC students get experience from top aviation

companies:

http://www.northlandsnewscenter.com/news/local/WITC-students-getting-

hands-on-experience--241729001.html?vid=a

The ABC’s of Composite Repair:

http://amt.epubxp.com/i/173697-sep-2013/29

2525

Overview of Advanced Composite

Technology Needs in Industry

Manufacturing

High Volume

* Limited Skill: Specialty training for use of limited automated equipment

Low Volume

* Highly skilled: Capable of fabrication in numerous hand and automated processes and assembly, read engineering drawings

Inspection/QA

Highly Skilled

* NDI certification* Composite technician

Skilled

* Composite technician with knowledge of NDI methods

Repair

Highly Skilled

* Certification for Aviation/Aero

Skilled

* Certification for marine, wind turbine industrial, etc.

2626

Manufacturing

Companies involved in fabrication of composite

structures will generally fall into one of two

categories: High volume or low volume/prototyping

High volume shops generally use labor that is more

“assembly line process”─ Technicians are really more production workers. Lower pay with

higher turn over rate

─ These shops will generally train their own people for specific

repetitious tasks

─ Colleges can train production workers within 1 semester and

provide a certificate

Low volume or prototype shops need technicians

capable of taking on numerous tasks with little to no

additional training─ Higher skilled labor, higher pay, lower turnover rate

─ Technicians usually will have a technical or associate degree

2727

Quality Assurance and Inspection

Quality control (assurance) is required in today’s

industry (both for fabrication and repair)

Generally companies will pull experienced people

with composite background to conduct inspections

for quality control purposes

To be an inspector requires knowledge of composite

structures, materials, fabrication methods, fabrication

flaws, damage assessment, and repair procedures

Some QA personnel will have background in the

different nondestructive inspection methods

QA personnel will generally hold a technical or

associate degree

2828

Repair

An advantage to composite structures is the ability to

produce very large single-piece parts

─ Aircraft structures, wind turbine blades, boat hulls, etc.

When these parts are damaged, they require repair

(too costly to scrap)

Repair technicians require knowledge in damage

assessment of composite structures, including

bolted and bonded joints

Repair technicians must be knowledgeable in the

numerous repair methods for composite structures,

joints, and bonded repairs to metal structures

Composite repairs in the aviation industry are the

most stringent (due to safety reasons). Procedures

and standards are set and enforced by FAA.

2929

Repair (continued)

Repair on aircraft requires A&P certification; however

FAA allows MROs to use trained composite repair

technicians that are not certified only if an A&P signs

off on work performed

─ Note that the FAA is working to change this in the future.

Goal is to allow MROs to define technician certification with

FAA approval. Similar to ISO quality standards used in

industry today

Aviation is not the only industry requiring trained

composite repair technicians

─ Repair processes used for wind turbine, marine, industrial

structures, etc. are similar to aviation, but without the

extensive documentation procedures

Colleges can train students for repair certification

within 1-2 semesters

3030

So What is the Direction for

Technical Colleges

Fact: The composite industry and demand for trained

technicians is growing

There is a growing need for colleges to provide

trained technicians. Identifying the viability of a

composite program is not easy. Evaluation includes:

─ Lack of knowledge in regards to this new technology

─ Scope of program to serve only the locality or the entire state

(assuming no other college in state offers)

─ Knowledge of the local (or state wide) industrial base for

demand of trained technicians, both now and in the future

Note: experience is showing that demand is growing faster than

preliminary estimates due to companies realizing that in-house training

is not as beneficial as training through the colleges, and a trained work

force tends to attract businesses

─ Budgets

─ Trained instructors (which there are few)

3131

Considerations

Composite technician programs are generally new to

technical colleges around the country

There is demand for trained technicians, but a lag in

colleges instituting composite programs. Although

budgets can be a factor, college personnel may not

be educated in the composite industry and demand

for technicians

Evaluating the scope for level of training

─ Does the school program only train specifically for local

businesses or offer broad, in-depth training to students that

allow them to find jobs in all industries and in all parts of the

country (or world)

3232

Considerations (continued)

The Boeing 787 has marked a pivotal point in the

history of aviation. All future plane designs will be

primarily composite. FAA has already acknowledged

the lack of trained composite repair technicians as

issue for continued air safety. So with that, where

does the FAA go in composite repair certification and

how do the technical schools answer?

Universities have answered the call for engineers

trained in composite structures. However, the tech

colleges are lagging in trained technicians. As one

manufacturing director lamented, “I can find

engineers no problem, I can’t find trained

technicians”

3333

Example for Repair Certification

Certification to meet 14 CFR Part 147 for composite

repair

─ Core competencies• Inspection of composite structures

• Assessment, evaluation and classification of damage

• Content and organization of OEM technical publications and instructions for

continued airworthiness

• Minor and major repairs on laminate structures using wet laid and pre-preg

materials

• Minor and major repairs on sandwich structures using wet laid and pre-preg

materials (including core replacement).

• Minor and major repairs of fractured or disbonded secondary bonds

• Removal and replacement of primary composite structures

─ Technologies• NDI ultrasonic inspection

• Resin and adhesive systems

• Reinforcement materials

• Vacuum bagging

• Pre-preg materials

• Field curing equipment (including bonding machines)

3434

Program Course Summaries

Industrial Safety: In-depth study of safety practices required in

industry. Topics include OSHA, Haz Mat, machine guarding,

PPEs (Personal Protective Equipment), shop practices, human

factors, electrical, overhead lifting, and more.

Introduction to Composites: Introduces PMCs (Polymer Matrix

Composites) with different fibers, resins, core materials, and

adhesives. Vacuum bagging and different curing processes.

Basic fabrication practices with numerous hands-on projects.

Role of Quality Assurance/Quality Control.

Composite Repair Fundamentals: Provide knowledge and

techniques for structural repair. Bonded and bolted repair,

adhesive joints, aviation requirements and use of AMMs

(Aircraft Maintenance Manuals) and SRMs (Structural Repair

Manuals). Numerous lab repair projects for hands on

experience.

3535

Program Course Summaries

(cont.)

Composite Fabrication: Fundamentals of numerous composite

structure fabrication methods. Hand layups with wet, prepreg,

and core materials, infusions, and automated processes

including filament winding, RTM, and fiber placement.

Assembly processes cover bonded and fastened joints.

Composite Test and Inspection: Covers various inspection

techniques and NDI methods used in repair and fabrication.

Destructive testing for defining material properties. Structural

test methods and instrumentation used. Course includes

numerous hands-on projects and use of NDI equipment.

Composite Machining: Trimming, drilling, and machining of

composite structures with different methods, special tools, and

techniques used. Introduction to CNC and coding. Outlines

differences between machining of metals and composites.

Numerous hands-on projects.

3636

Program Course Summaries

(cont.)

Tooling for Composite Fabrication: Introduces numerous types

of tools/molds used in composite industry. Gain understanding

of tool design, manufacture, maintenance, and repair. Students

fabricate soft (foam) tools from CNC and composite tools from

plugs, patterns, or 3D printed parts. Work with sealants, fillers,

and gel coats.

Composite Design: Students gain understanding of material’s

orthotropic nature, do’s and don’ts of design layups, loading in

different environments, designing monolithic and sandwich core

structures, and bolted and bonded joint designs. Course

outlines different composite designs found in the different

industries

PLM/Catia/Enovia: Students learn to retrieve drawings,

composite layups, part, and assembly information from

electronic databases. Students develop understanding of PLM

3737

Program Course Summaries

(cont.)

Engineering Drawings: Students learn how to read and interpret

engineering drawings (including composite drawings) per ASME

Y-14. Course includes understanding of geometric

dimensioning and tolerancing.

Aircraft Familiarization: Provides introduction to aircraft

systems and construction. Focus is on structures and role of

federal regulations regarding certification and repairs.

Internship/Research Project: Students intern with local

composite company or participate in research project to gain

real world experience.

3838

Personal Biographies of

Instructors

Dave Crockett

─ Owner of Osprey Technologies, LLC.- composite engineering

firm located in Arizona

─ Over 30 years as mechanical engineer specializing in

composite structural analysis, design, fabrication, and test

─ Developer and instructor for composite program at WITC

Superior, WI

Tim Wright

─ 18 years as an A&P mechanic and technical trainer

─ Technical instructor for Cirrus Aircraft. Trained over 250

engineers, technicians, A&P instructors, and regulatory

agents on aircraft composite damage assessment and repair

─ Developer and instructor for composite program at WITC

Superior, WI

─ Developed composite program for Northland Community and

Technical College