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Manufacturing & Marine · course plan
⚠ Pending professional review
This course plan, its lessons and its assessments has not yet been verified by a licensed engineer or certified journey-level tradesperson or by a certification or approval body. It is a study draft and may contain errors. Do not use it as instructions for work on a job site or on live equipment. Always follow your instructor, your supervising professional, and current official references and regulations.
VoTechWorks program approval and accreditation are still in progress. Credentials are issued only by the certifying bodies named in each program, after their own exams.
Fiberglass / Composites (boatbuilding)
9 courses · 900 clock hours · 6 mo full-time. Grading is competency-based: each course requires the written exam, a competent skills demonstration with zero safety faults, a signed log, and a passed safety audit; percentage weights only rank performance above the competency floor.
9courses
54lessons
900hours
31assessments
Development progressPlanCourses, lessons and assessments written for this tradeLessons54 of 54 lesson pages writtenPractice430 practice questionsResources117 reference entries (study list)Review0 lesson pages reviewed by a licensed professional
Study now: 54 lesson pages are open (lesson titles below are links).
MFG-COMP18-01 Universal core
Universal Core: Safety, Math, Communication & Career — Fiberglass & Composites Boatbuilding
148 hr · $1,185 COMPLIMENTARY
This foundational course equips adult learners with the safety knowledge, trade mathematics, technical literacy, digital skills, and career-readiness habits required before touching any composite materials or equipment. Every topic is contextualized to fiberglass boatbuilding and the ABYC and ACMA CCT credential domains so that later technical courses build on a solid, verified base.
Outcomes- Complete OSHA 10-Hour General Industry training and demonstrate correct hazard-identification and lockout/tagout procedures in a shop walk-through.
- Perform first aid and CPR to the standard required for certification, including response to chemical splash, respiratory distress from styrene or acetone exposure, and laceration from fiberglass.
- Apply trade math — fractions, ratios, unit conversion, geometric area and volume, and weight-to-volume resin calculations — accurately on boatbuilding problems with no more than 2% error.
- Read and interpret technical documents including ABYC standards summaries, safety data sheets (SDS), laminate schedules, and work orders using correct composites terminology.
- Use basic digital tools — spreadsheets for mix-ratio tracking, email for workplace communication, and job-search platforms — to support shop and career tasks.
- Construct a personal career plan that maps the ABYC Composite Boat Builder and ACMA CCT credential requirements to a realistic pathway toward employment in the marine composites industry.
Course text
This foundational course equips adult learners with the safety knowledge, trade mathematics, technical literacy, digital skills, and career-readiness habits required before touching any composite materials or equipment. Every topic is contextualized to fiberglass boatbuilding and the ABYC and ACMA CCT credential domains so that later technical courses build on a solid, verified base.
How the course runs. 7 blocks: Hazard Recognition and OSHA 10 — Marine Composites Shop; PPE Selection, Respiratory Protection, and First Aid/CPR; Trade Math — Measurement, Ratios, and Resin Calculations; Reading Technical Documents — SDS, ABYC Standards, and Laminate Schedules; Composites Industry Vocabulary and Technical Communication; Digital Tools for the Composites Shop and Job Search; Career Planning — Credentials, Pathways, and Professional Identity.
What competent looks like. Complete OSHA 10-Hour General Industry training and demonstrate correct hazard-identification and lockout/tagout procedures in a shop walk-through. Perform first aid and CPR to the standard required for certification, including response to chemical splash, respiratory distress from styrene or acetone exposure, and laceration from fiberglass. Apply trade math — fractions, ratios, unit conversion, geometric area and volume, and weight-to-volume resin calculations — accurately on boatbuilding problems with no more than 2% error. Read and interpret technical documents including ABYC standards summaries, safety data sheets (SDS), laminate schedules, and work orders using correct composites terminology. Use basic digital tools — spreadsheets for mix-ratio tracking, email for workplace communication, and job-search platforms — to support shop and career tasks. Construct a personal career plan that maps the ABYC Composite Boat Builder and ACMA CCT credential requirements to a realistic pathway toward employment in the marine composites industry.
| # | Lesson | Hr | Type | Objective | Activities | Materials | Check |
|---|---|---|---|---|---|---|---|
| 1 | Hazard Recognition and OSHA 10 — Marine Composites Shop | 30 | theory | Students will identify the primary physical, chemical, and ergonomic hazards present in a fiberglass boatbuilding shop and correctly apply OSHA General Industry hazard-control principles to each. |
| OSHA OTI OSHA 10 General Industry course materials; 29 CFR 1910.147 reference card; shop hazard-identification checklist (instructor-prepared); blank LOTO permit forms; SDS binder for polyester resin, vinyl ester resin, epoxy, acetone, MEKP, styrene, gel coat. | OSHA 10 card issued upon course completion; shop walk-through checklist must identify ≥ 15 of 20 targeted hazards (75% pass); LOTO permit must have all required fields correct with zero critical steps missing. |
| 2 | PPE Selection, Respiratory Protection, and First Aid/CPR | 24 | demo | Students will select appropriate PPE for each composites task, demonstrate correct respirator fit-check and donning, and perform adult CPR and first aid to the standard required for certification. |
| Assorted PPE samples (gloves, goggles, face shields, half-face respirators, Tyvek suits, hearing protection); qualitative fit-test kit; AHA Heartsaver student workbooks and manikins; AED trainer; eye-wash station; first-aid kit; SDS binder. | Valid First Aid/CPR certification card upon completion; PPE task-matching exercise ≥ 80% correct; respirator fit-test logged with passing result; debrief Q&A — instructor verifies student can state minimum cartridge-change frequency and eye-wash flush duration without prompting. |
| 3 | Trade Math — Measurement, Ratios, and Resin Calculations | 28 | lab | Students will accurately perform unit conversion, area and volume calculations, and resin mix-ratio and catalyst percentage calculations relevant to laminate schedule preparation, with no more than 2% error on a timed problem set. |
| Digital calipers; tape measures; platform scale (0.1 g resolution); fiberglass fabric samples; polyester resin and MEKP (small quantities for practice batches); mixing cups and stir sticks; scientific calculators; printed worksheet packet; answer key; SDS for resin and catalyst. | Timed 20-question math quiz covering all skill areas — pass mark 80%; resin-mix lab: all three batches within ±2% of target catalyst weight; measurement data table reviewed by instructor for correct unit conversions. |
| 4 | Reading Technical Documents — SDS, ABYC Standards, and Laminate Schedules | 22 | theory | Students will locate specific safety, material, and construction information within SDS documents, ABYC standards summaries, and a marine laminate schedule, demonstrating comprehension by answering targeted questions with 80% accuracy. |
| SDS documents (polyester resin, epoxy, acetone — current manufacturer versions); printed ABYC standards summaries (instructor-curated excerpts, copyright-compliant); sample laminate schedule handout; SDS question sheet; annotation pens; whiteboard for group debrief. | SDS question sheet ≥ 80% correct; laminate schedule questions ≥ 80% correct; participation in standards discussion confirmed by instructor observation checklist. |
| 5 | Composites Industry Vocabulary and Technical Communication | 14 | theory | Students will correctly use standard composites and marine industry terminology in written and spoken communication, including in a work-order response and a verbal toolbox-talk scenario. |
| Vocabulary term and definition card sets (instructor-prepared); sample work order (instructor-prepared); memo rubric; toolbox-talk topic cards; peer observation forms; whiteboard; SDS binder. | Vocabulary card sort ≥ 80% correct; work-order memo scored ≥ 80% on rubric (terminology, clarity, completeness); toolbox talk scored ≥ 80% on peer/instructor observation form for accuracy and correct PPE/hazard references. |
| 6 | Digital Tools for the Composites Shop and Job Search | 14 | practice | Students will use spreadsheet software to build a resin mix-ratio tracking log and use professional digital communication and job-search platforms to locate and respond to a real entry-level marine composites job posting. |
| Computers or tablets with spreadsheet software (Google Sheets or Microsoft Excel); internet access; email accounts; job-board websites; ABYC and ACMA website access; email rubric; spreadsheet specification checklist. | Spreadsheet file meets all checklist items (correct formulas, conditional formatting triggers accurately) — pass = all required functions present and operating; email drafts score ≥ 80% on rubric; job-search table submitted with three postings and credential mapping completed. |
| 7 | Career Planning — Credentials, Pathways, and Professional Identity | 16 | field | Students will construct a written personal career plan that accurately describes the ABYC Composite Boat Builder and ACMA CCT credential requirements and maps them to a realistic 12-month post-graduation employment pathway. |
| Current ABYC Composite Boat Builder and ACMA CCT credential information (from abycinc.org and acmanet.org, accessed directly); guest speaker or video-conferencing platform; credential comparison chart template; career plan rubric; word-processing software. | Career plan scored with rubric: pass = plan accurately describes both credentials, maps ≥ 4 program courses to credential exam domains, includes a realistic timeline — minimum score 80%; credential comparison chart reviewed by instructor for factual accuracy with zero critical errors (e.g., wrong eligibility requirement). |
| Assessment | Type | Weight | Pass standard | Method & rubric |
|---|---|---|---|---|
| OSHA 10 & Safety Knowledge Exam | Written exam | 25% | 70% or higher on all sections; OSHA 10 card must be earned to pass this assessment regardless of written score. | A 50-question written exam covering OSHA General Industry hazard recognition, hierarchy of controls, lockout/tagout procedures, PPE selection for composites tasks, SDS interpretation, and first-aid response to chemical and physical injuries typical in a fiberglass shop. Questions are drawn from Lessons 1 and 2 and are formatted to mirror the question style used in ABYC and ACMA exam domains on safety. Accuracy · Safety · Communication · Professionalism |
| Trade Math and Technical Reading Exam | Written exam | 25% | 80% overall; no individual section (math or reading) below 75%. | A 40-question closed-book exam combining timed trade-math problems (unit conversion, area/volume, resin ratio calculations) and technical-reading comprehension questions requiring students to extract specific information from a provided SDS excerpt and a sample laminate schedule. This assessment directly maps to the quantitative and documentation competency domains tested on the ACMA CCT exam. Accuracy · Safety · Communication · Professionalism |
| Digital Portfolio — Spreadsheet, Professional Communication, and Career Plan | Project | 25% | Each of the three components must score ≥ 80% on its respective rubric; a failing component must be revised and resubmitted within one week. | Students submit their completed resin-tracking spreadsheet, two professional emails, and their personal career plan as a single digital portfolio package. The instructor evaluates each item against the rubrics introduced during Lessons 6 and 7, with particular attention to formula accuracy, professional tone, and factual correctness of credential information — skills that support workplace communication competencies addressed in the ACMA CCT exam framework. Accuracy · Safety · Communication · Professionalism |
| Safety and Trade Knowledge Oral Defense | Oral / panel | 25% | Student must answer at least 4 of 5 questions correctly and demonstrate PPE donning without prompting to pass; a single re-attempt is permitted within one week. | A 15-minute one-on-one oral session in which the instructor poses five scenario-based questions drawn randomly from all lesson areas (e.g., describe the LOTO procedure for a specific tool, identify the error in a given resin-batch calculation, explain what an SDS flash-point value means for storage). The student also physically dons and doffs a half-face respirator and chemical splash goggles while narrating their process, demonstrating the hands-on safety competency that underpins both the ABYC and ACMA credential practical expectations. Accuracy · Safety · Communication · Professionalism |
MFG-COMP18-02 Trade course
Mold Making for Fiberglass and Composite Boatbuilding
88 hr · $1,320 COMPLIMENTARY
Students learn to build, maintain, and release production-quality fiberglass molds from plug to finished tool, covering plug preparation, tooling gelcoat and laminate schedules, release systems, and mold quality inspection. Lessons are grounded in ABYC and ACMA standards for tooling materials, dimensional accuracy, and surface finish. Successful completion prepares students to evaluate mold condition and execute mold-making sequences used in production boatbuilding shops.
Outcomes- Select appropriate plug materials and prepare a plug surface to a production-ready finish verified by gloss and profile measurements.
- Apply a multi-coat release system and tooling gelcoat to a plug following manufacturer specifications and ACMA CCT tooling guidelines.
- Laminate a female mold using a tooling laminate schedule that meets minimum thickness and fiber-volume requirements for dimensional stability.
- Perform mold release, inspect the finished mold for defects such as porosity, print-through, and warpage, and document findings on a mold inspection form.
- Safely handle, store, and dispose of tooling resins, styrene-containing materials, and solvents in compliance with OSHA Hazard Communication (HazCom) standards and applicable SDS requirements.
- Demonstrate mold maintenance procedures including waxing, buffing, and minor surface repair to sustain mold life and part quality.
Course text
Students learn to build, maintain, and release production-quality fiberglass molds from plug to finished tool, covering plug preparation, tooling gelcoat and laminate schedules, release systems, and mold quality inspection. Lessons are grounded in ABYC and ACMA standards for tooling materials, dimensional accuracy, and surface finish. Successful completion prepares students to evaluate mold condition and execute mold-making sequences used in production boatbuilding shops.
How the course runs. 7 blocks: Mold Theory, Tooling Concepts, and Safety for Mold Making; Plug Design, Materials Selection, and Dimensional Layout; Plug Surface Preparation: Filling, Fairing, and Final Finish; Release Systems: Sealing, Waxing, and Semi-Permanent Release Agents; Tooling Gelcoat and Skin Coat Application; Build-Up Laminate, Flanges, and Stiffener Integration; Mold Release, Inspection, Repair, and Maintenance.
What competent looks like. Select appropriate plug materials and prepare a plug surface to a production-ready finish verified by gloss and profile measurements. Apply a multi-coat release system and tooling gelcoat to a plug following manufacturer specifications and ACMA CCT tooling guidelines. Laminate a female mold using a tooling laminate schedule that meets minimum thickness and fiber-volume requirements for dimensional stability. Perform mold release, inspect the finished mold for defects such as porosity, print-through, and warpage, and document findings on a mold inspection form. Safely handle, store, and dispose of tooling resins, styrene-containing materials, and solvents in compliance with OSHA Hazard Communication (HazCom) standards and applicable SDS requirements. Demonstrate mold maintenance procedures including waxing, buffing, and minor surface repair to sustain mold life and part quality.
| # | Lesson | Hr | Type | Objective | Activities | Materials | Check |
|---|---|---|---|---|---|---|---|
| 1 | Mold Theory, Tooling Concepts, and Safety for Mold Making | 10 | theory | Students will explain the purpose and anatomy of a production mold, identify tooling materials, and correctly interpret Safety Data Sheets for tooling gelcoat, tooling resin, and release agents. |
| ABYC Composite Boat Builder reference materials, ACMA CCT Technician Study Guide, tooling resin and gelcoat SDS packets, mold cross-section diagram handout, dry-erase board, PPE (nitrile gloves, safety glasses, P100/OV respirator for any live product demonstrations) | Students score 80% or higher on a 20-question written quiz covering mold anatomy, material identification, and SDS interpretation; each student must correctly identify required PPE for tooling gelcoat application before entering any subsequent lab. |
| 2 | Plug Design, Materials Selection, and Dimensional Layout | 12 | demo | Students will read a simple part drawing, calculate plug dimensions including draft angle and flange allowances, and select appropriate plug-building materials for a given part geometry. |
| Part drawing (hull section, instructor-supplied), scale rule, bevel gauge, protractor, framing square, flexible tape measure, MDF offcuts, tooling board sample, foam sample, body filler sample, parting-line tape, dry-erase marker, PPE (safety glasses, dust mask for MDF cutting) | Instructor verifies that each student's flange layout is within 1/8 inch of the drawing dimension and that draft-angle calculations are correct; any error greater than one degree in draft angle requires rework before proceeding. |
| 3 | Plug Surface Preparation: Filling, Fairing, and Final Finish | 14 | lab | Students will fill, fair, and sand a plug surface to a high-gloss finish with no visible low spots greater than 0.020 inches as measured with a metal straightedge. |
| MDF panel plug blanks, automotive body filler, polyester or epoxy high-build primer, wet/dry sandpaper (80–1200 grit), longboard sander, random-orbit sander, rotary polisher, cutting compound, metal straightedge, 0.020-inch feeler gauge, chalk, plug inspection checklist, PPE (P100/OV respirator, nitrile gloves, safety glasses, Tyvek suit) | Plug surface passes instructor inspection: zero low spots greater than 0.020 inches on the straightedge-and-feeler-gauge check, visible gloss with clear reflection of a fluorescent tube; students who do not pass re-sand and recheck within the same lab session. |
| 4 | Release Systems: Sealing, Waxing, and Semi-Permanent Release Agents | 10 | demo | Students will apply a complete multi-step release system to a prepared plug surface, demonstrating correct number of coats, cure times, and buffing technique for both paste wax and semi-permanent release agents. |
| Prepared MDF test panels (finished to gloss from Lesson 3), paste mold release wax (carnauba-based, marine tooling grade), semi-permanent release agent (manufacturer-recommended product), PVA mold release (optional), clean cotton cloths, soft buffing pads, spray bottle, lab notebook, timer, PPE (nitrile gloves, safety glasses, ventilation) | Instructor wipes a 2-inch patch of each student's waxed panel with a dark cloth; no wax transfer on the cloth after the final buff indicates adequate cure; PVA film (if applied) is visually checked for complete, pinhole-free coverage — any missed spot or bubble requires the student to re-apply that area. |
| 5 | Tooling Gelcoat and Skin Coat Application | 16 | lab | Students will catalyze and spray or brush tooling gelcoat to a uniform 20–25 mil wet-film thickness and apply a skin coat of tooling resin and 1.5 oz chopped-strand mat within the gelcoat's green-cure window. |
| Tooling gelcoat (pigmented, tooling grade), MEKP catalyst, tooling laminating resin, 1.5 oz chopped-strand mat, digital gram scale, wet-film thickness gauge, HVLP or conventional spray gun, air compressor, mixing cups and sticks, stipple roller, chip brushes, acetone (for cleanup), disposable mixing containers, lab log, PPE (full-face respirator with OV/P100 cartridges, nitrile gloves, Tyvek suit, safety glasses) | Wet-film gauge readings at five points must average 20–25 mil with no single point below 18 mil; skin coat is checked by instructor tap test for voids — zero unbonded zones permitted; students with failing panels must identify root cause in writing before re-spraying. |
| 6 | Build-Up Laminate, Flanges, and Stiffener Integration | 14 | lab | Students will complete a mold laminate schedule by applying build-up plies and perimeter flanges to achieve a minimum cured laminate thickness specified on the schedule, and bond or integrate stiffening structure. |
| Tooling laminate schedule (instructor-issued), 1.5 oz chopped-strand mat, 24 oz woven roving, tooling resin, MEKP, gram scale, segmented steel roller, mixing containers, calipers (0–6 inch), framing square, fiberglass or plywood stiffener stock, secondary bond adhesive or wet-laminate materials, scissors, marking pen, lab log, PPE (full-face respirator OV/P100, nitrile gloves, Tyvek, safety glasses) | Cured laminate thickness is measured with calipers at six points; all readings must meet or exceed the scheduled minimum (typically 3/8 inch for a demonstration mold of this size); flange width is verified at 2 inches minimum at all four corners; any point below minimum requires an additional ply before sign-off. |
| 7 | Mold Release, Inspection, Repair, and Maintenance | 12 | practice | Students will demold a cured mold from its plug without damage, perform a full mold inspection using a standardized checklist, repair identified surface defects, and execute a first-production wax maintenance cycle. |
| Cured mold panels from Lesson 6, wooden wedges, mold inspection checklist, 12-inch metal straightedge, feeler gauge, calipers, wet/dry sandpaper (400–1200 grit), cutting compound, polishing compound, rotary polisher, paste mold release wax, cotton cloths, buffing pads, lab log, camera or phone for documentation, PPE (safety glasses, nitrile gloves, dust mask for sanding, OV respirator for polishing compounds) | Mold inspection form must be fully completed with no blank fields; at least one defect must be identified and have a written corrective-action plan; repaired and waxed surface must pass instructor gloss check (clear tube reflection visible) — incomplete forms or insufficient gloss result in repeat of the wax and buff cycle with re-inspection. |
| Assessment | Type | Weight | Pass standard | Method & rubric |
|---|---|---|---|---|
| Mold Making Written Knowledge Exam | Written exam | 25% | 80% correct (32 of 40 questions) | A 40-question multiple-choice and short-answer exam covering mold anatomy, plug material selection, tooling gelcoat and laminate schedule interpretation, release systems, MEKP catalyst safety, SDS requirements, and mold inspection criteria; questions are mapped to ABYC Composite Boat Builder and ACMA CCT tooling knowledge areas. Standard met · Safety · Time · Quality/finish · Documentation |
| Mold Making Skills Demonstration | Skills demonstration | 45% | All six rubric categories scored at 'Meets Standard' or higher; no category may be scored 'Below Standard' | The student independently prepares a plug surface, applies a release system, sprays or brushes tooling gelcoat to the specified wet-film thickness, and laminates a two-ply skin coat within the green-cure window; an instructor evaluates each step on a six-category rubric (surface prep, catalyst ratio accuracy, wet-film gauge readings, consolidation quality, flange execution, and safe work practices) aligned to ACMA CCT and ABYC performance standards. Standard met · Safety · Time · Quality/finish · Documentation |
| Mold Making Lab Log | Log | 15% | Complete entries for all seven lessons; each entry scores 80% or higher on the lab-log rubric | The student submits a lab log with dated entries for every lab and practice session, including material batch calculations (resin weight, catalyst weight, ratio), wet-film gauge readings, laminate thickness measurements, cure observations, defect descriptions, and corrective actions taken; the log is evaluated for accuracy, completeness, and evidence that the student connected measurements to quality outcomes. Standard met · Safety · Time · Quality/finish · Documentation |
| Safety and Hazard-Communication Verification Check | Safety audit | 15% | 100% correct on all five safety checkpoints; any failed checkpoint requires immediate remediation and recheck before the student may re-enter the spray or laminating area | Instructor administers a five-point safety verification at the start of the tooling gelcoat lab (Lesson 5): correct respirator cartridge type fitted and seal-checked, appropriate gloves donned, SDS location identified and emergency section cited from memory, catalyst added to resin (never resin to catalyst) demonstrated in correct order, and ventilation system confirmed operational; this check is repeated at the start of every subsequent lab session and is a prerequisite for lab participation. Standard met · Safety · Time · Quality/finish · Documentation |
MFG-COMP18-03 Trade course
Hand Layup and Wet Lamination for Composite Boatbuilding
88 hr · $1,320 COMPLIMENTARY
Students master the theory and hands-on practice of open-mold hand layup using polyester, vinyl ester, and epoxy resin systems with woven, chopped-strand, and multiaxial reinforcements common in production boatbuilding. Lessons progress from resin chemistry and laminate schedule reading through full hull-section builds, with emphasis on fiber wet-out, air removal, and achieving the laminate thickness and fiber-volume ratio specified by the designer. All work is mapped to ACMA CCT competency domains and ABYC Composite Boat Builder exam areas covering materials, processes, and quality control.
Outcomes- Select the correct resin system, catalyst/hardener ratio, and reinforcement schedule for a given marine laminate specification and ambient conditions.
- Execute a hand layup sequence—surface coat, barrier coat, and structural plies—that meets a written laminate schedule within ±10% of target thickness and shows complete wet-out with no dry fiber or entrapped air.
- Correctly mix catalyzed polyester or vinyl ester resin, verifying gel time with a recorded batch log before application.
- Use squeegees, rollers, and consolidation tools to achieve void-free laminate, confirmed by visual inspection and a thickness gauge reading.
- Apply personal protective equipment (respirator, gloves, eye protection) and ventilation controls required by the SDS for each resin and reinforcement used, and demonstrate safe handling and disposal of resin waste.
- Read and record laminate build data on a ply-by-ply inspection log that meets a shop quality-control standard, supporting ACMA CCT documentation requirements.
Course text
Students master the theory and hands-on practice of open-mold hand layup using polyester, vinyl ester, and epoxy resin systems with woven, chopped-strand, and multiaxial reinforcements common in production boatbuilding. Lessons progress from resin chemistry and laminate schedule reading through full hull-section builds, with emphasis on fiber wet-out, air removal, and achieving the laminate thickness and fiber-volume ratio specified by the designer. All work is mapped to ACMA CCT competency domains and ABYC Composite Boat Builder exam areas covering materials, processes, and quality control.
How the course runs. 7 blocks: Resin Systems: Chemistry, Hazards, and Selection; Reinforcement Materials and Laminate Schedule Reading; PPE, Ventilation, and Safe Resin Handling (Safety Check Lesson); Resin Mixing, Gel-Time Testing, and Batch Logging; Hand Layup Fundamentals: Wet-Out, Consolidation, and Air Removal; Contoured Mold Layup: Hull Section Build; Laminate Defects, Troubleshooting, and ACMA/ABYC Quality Standards.
What competent looks like. Select the correct resin system, catalyst/hardener ratio, and reinforcement schedule for a given marine laminate specification and ambient conditions. Execute a hand layup sequence—surface coat, barrier coat, and structural plies—that meets a written laminate schedule within ±10% of target thickness and shows complete wet-out with no dry fiber or entrapped air. Correctly mix catalyzed polyester or vinyl ester resin, verifying gel time with a recorded batch log before application. Use squeegees, rollers, and consolidation tools to achieve void-free laminate, confirmed by visual inspection and a thickness gauge reading. Apply personal protective equipment (respirator, gloves, eye protection) and ventilation controls required by the SDS for each resin and reinforcement used, and demonstrate safe handling and disposal of resin waste. Read and record laminate build data on a ply-by-ply inspection log that meets a shop quality-control standard, supporting ACMA CCT documentation requirements.
| # | Lesson | Hr | Type | Objective | Activities | Materials | Check |
|---|---|---|---|---|---|---|---|
| 1 | Resin Systems: Chemistry, Hazards, and Selection | 10 | theory | Students will identify the chemical families (polyester, vinyl ester, epoxy), explain cure mechanisms, state the relevant SDS hazard sections, and select the appropriate resin for a marine application based on service requirements. |
| Labeled resin samples (GP polyester, vinyl ester, epoxy), current SDS packets, ACMA Composites Manufacturing textbook, manufacturer TDS sheets, calculators, PPE (nitrile gloves, safety glasses, half-face respirator with organic-vapor cartridges) | Written quiz: 10 questions on resin properties, cure chemistry, and SDS hazard identification; pass = 80% or higher. |
| 2 | Reinforcement Materials and Laminate Schedule Reading | 10 | theory | Students will identify woven roving, chopped strand mat, biaxial and triaxial cloth, and core materials by fiber architecture, state their typical areal weights, and extract ply sequence and thickness targets from a written laminate schedule. |
| Reinforcement sample library (1.5 oz CSM, 24 oz WR, 17 oz biaxial, 54 oz triaxial, Corecell foam core, balsa core), sample laminate schedule document, ACMA textbook Chapter on reinforcements, rulers, marker pens | Identification worksheet: students correctly label all seven reinforcement samples and answer all five schedule comprehension questions; pass = 80% correct. |
| 3 | PPE, Ventilation, and Safe Resin Handling (Safety Check Lesson) | 8 | demo | Students will don full layup PPE in the correct sequence, verify local exhaust ventilation is functioning, mix a small catalyzed resin batch safely, and dispose of resin waste per shop procedure without a single procedural error observed by the instructor. |
| Tyvek suits (assorted sizes), chemical-splash goggles, face shields, nitrile gloves, half-face respirators with OV/P100 cartridges, GP polyester resin, MEKP catalyst, digital scale, mixing sticks, labeled waste containers, LEV hood, shop ventilation checklist, SDS binder | Instructor observational checklist (24 items covering PPE, ventilation, mixing, labeling, and disposal): zero critical errors allowed; any critical error (wrong respirator cartridge, reversed glove protocol, improper waste disposal) requires immediate re-demonstration before proceeding. |
| 4 | Resin Mixing, Gel-Time Testing, and Batch Logging | 10 | lab | Students will mix five successive polyester resin batches at varying catalyst percentages and temperatures, predict gel time using the TDS chart, measure actual gel time with a timer and rod test, and record all data accurately on a batch log. |
| GP polyester resin, MEKP catalyst, digital scale (±1 g), mixing cups, mixing sticks, thermometer, stopwatch, TDS gel-time chart, batch log forms, PPE (as Lesson 3) | Batch log completeness check: all five entries include weight, catalyst %, temperature, predicted gel time, actual gel time, and difference; actual gel times within ±20% of TDS prediction for at least four of five batches; log passed = all fields complete and four-of-five accuracy criterion met. |
| 5 | Hand Layup Fundamentals: Wet-Out, Consolidation, and Air Removal | 18 | practice | Students will apply resin to a flat 24 × 24-inch panel using the correct stippling and rolling sequence to achieve full fiber wet-out and consolidate a three-ply laminate schedule with no dry spots or visible voids, confirmed by thickness measurement within ±10% of target. |
| Waxed flat mold boards, GP polyester resin, MEKP, 1.5 oz CSM, 24 oz woven roving, laminating brushes, squeegees, ribbed aluminum rollers, digital thickness gauge, strong inspection lamp, china marker, camera or phone, PPE | Completed panel: thickness average within ±10% of schedule target at seven of nine grid points; no dry fiber visible under inspection lamp; no voids found on tap test larger than 1 inch diameter; pass requires all three criteria met. |
| 6 | Contoured Mold Layup: Hull Section Build | 22 | lab | Students will apply a release agent, lay up a full laminate schedule on a contoured hull-section mold, achieve continuous wet-out around curves and into the bilge radius, and produce a demolded part that meets the written schedule for ply count, average thickness, and visual quality. |
| Contoured hull-section mold (fiberglass female mold), paste wax, PVA release film, GP polyester gel coat, GP laminating resin, MEKP, 1.5 oz CSM, 24 oz WR, laminating brushes, squeegees, rollers, digital thickness gauge, trim saw, wooden wedge set, quality audit form, PPE | Quality audit form reviewed by instructor: ply count matches schedule; average thickness at all twelve points within ±10% of target; no unbonded areas larger than 0.5 inch on tap test; part successfully demolded without mold damage; all deviations documented with cause and corrective action; pass requires all criteria met. |
| 7 | Laminate Defects, Troubleshooting, and ACMA/ABYC Quality Standards | 10 | theory | Students will identify at least eight common hand-layup defects from photographs and sample panels, state the root cause and prevention for each, and apply ACMA CCT and ABYC Composite Boat Builder quality acceptance criteria to classify whether a defect is accept, monitor, or repair. |
| Defect sample panel library, printed ABYC composite construction standard excerpts, ACMA CCT study guide quality section, defect identification worksheets, classification exercise handout, projector for photo display | Defect worksheet + classification exercise: correct identification and cause for at least seven of eight defect types on worksheet; correct classification with written justification for at least eight of ten photographs; pass = both sub-scores met. |
| Assessment | Type | Weight | Pass standard | Method & rubric |
|---|---|---|---|---|
| Layup Theory Knowledge Exam | Written exam | 25% | 75% or higher (38 of 50 questions correct) | A 50-question written exam covering resin chemistry and selection, reinforcement types and areal weights, laminate schedule interpretation, catalyst ratio calculation, defect identification, and ABYC/ACMA quality acceptance criteria. Questions are formatted as multiple-choice and short-answer to mirror the style of ACMA CCT and ABYC Composite Boat Builder credential exams. Standard met · Safety · Time · Quality/finish · Documentation |
| Hull-Section Layup Skills Demonstration | Skills demonstration | 45% | All four quality criteria met: ply count matches schedule; average thickness within ±10% of target at ten of twelve measurement points; no unbonded areas larger than 0.5 inch; mold undamaged after demold | Each student independently laminates a specified four-ply schedule on a contoured hull-section mold without coaching, completing mold prep, gel coat, structural plies, and demold within a single work session. The instructor measures and records thickness, performs a full tap test, and scores the part against the four published criteria. Standard met · Safety · Time · Quality/finish · Documentation |
| Laminate Build Lab Log | Log | 15% | All seven required entries complete and accurate; batch calculations verified correct; deviations documented with cause and corrective action; legible and organized | Students submit the cumulative lab notebook maintained across all seven lessons, including batch logs (weight, catalyst %, temperature, predicted and actual gel times), ply-by-ply layup records for both the flat panel and hull-section builds, thickness measurement data sheets, quality audit forms, and the defect classification exercise. The log is reviewed for completeness, numerical accuracy, and the quality of deviation analysis. Standard met · Safety · Time · Quality/finish · Documentation |
| PPE and Safe Resin Handling Safety Check | Safety audit | 15% | Zero critical errors on the 24-item observational checklist; any critical error requires immediate re-demonstration before the student may continue lab work | The instructor administers a live observational check during Lesson 3 and again unannounced during the hull-section layup in Lesson 6, scoring each student against the 24-item checklist that covers PPE donning sequence, respirator fit check, ventilation verification, resin batch labeling, gel-watch procedure, and waste disposal. This safety check is a prerequisite gate: students who do not pass cannot advance to the Vacuum Infusion course. Standard met · Safety · Time · Quality/finish · Documentation |
MFG-COMP18-04 Trade course
Vacuum Infusion for Composite Boatbuilding
87 hr · $1,305 COMPLIMENTARY
Students learn to produce structural composite parts using vacuum-assisted resin infusion (VARI), covering process theory, tooling and consumables setup, flow media and resin-feed network design, infusion execution, troubleshooting, and quality evaluation. Lessons align with ACMA CCT knowledge domains for closed-mold processes and ABYC composite standards for laminate integrity. Emphasis is placed on hazard control for styrene and mixed-resin systems, correct vacuum-integrity testing, and documenting process variables to meet production traceability requirements.
Outcomes- Explain the physical principles of vacuum-assisted resin infusion and compare the process to open-mold hand layup in terms of fiber volume fraction, VOC emissions, and laminate consistency.
- Set up a complete infusion stack — including peel ply, flow media, feed and vacuum lines, and vacuum bag — on a marine-grade mold without assistance, achieving and holding a vacuum level within the acceptable range for the resin system in use.
- Design and execute a resin-feed network for a flat panel and a simple curved hull section, controlling infusion front progression to eliminate dry spots.
- Mix infusion-grade vinyl ester or epoxy resin within the manufacturer's specified pot-life window, record batch records, and complete infusion before gel.
- Identify, diagnose, and correct the five most common infusion defects — bag leak, dry spot, race-tracking, bridging, and resin starvation — using established troubleshooting procedures.
- Demonstrate full PPE compliance, safe handling of catalyzed resin under vacuum, and emergency shutdown procedures consistent with OSHA 29 CFR 1910 Subpart Z chemical-hazard requirements and ACMA CCT safety competencies.
Course text
Students learn to produce structural composite parts using vacuum-assisted resin infusion (VARI), covering process theory, tooling and consumables setup, flow media and resin-feed network design, infusion execution, troubleshooting, and quality evaluation. Lessons align with ACMA CCT knowledge domains for closed-mold processes and ABYC composite standards for laminate integrity. Emphasis is placed on hazard control for styrene and mixed-resin systems, correct vacuum-integrity testing, and documenting process variables to meet production traceability requirements.
How the course runs. 7 blocks: Infusion Process Theory and Closed-Mold Fundamentals; Chemical Hazards, PPE, and Ventilation for Infusion Resins; Tooling, Consumables, and Infusion Stack Setup; Resin Feed Network Design and Infusion Front Control; Resin Mixing, Pot Life, and Process Documentation; Defect Recognition, Troubleshooting, and Quality Inspection; Integrated Infusion Build: Marine Hull Panel with Full Documentation.
What competent looks like. Explain the physical principles of vacuum-assisted resin infusion and compare the process to open-mold hand layup in terms of fiber volume fraction, VOC emissions, and laminate consistency. Set up a complete infusion stack — including peel ply, flow media, feed and vacuum lines, and vacuum bag — on a marine-grade mold without assistance, achieving and holding a vacuum level within the acceptable range for the resin system in use. Design and execute a resin-feed network for a flat panel and a simple curved hull section, controlling infusion front progression to eliminate dry spots. Mix infusion-grade vinyl ester or epoxy resin within the manufacturer's specified pot-life window, record batch records, and complete infusion before gel. Identify, diagnose, and correct the five most common infusion defects — bag leak, dry spot, race-tracking, bridging, and resin starvation — using established troubleshooting procedures. Demonstrate full PPE compliance, safe handling of catalyzed resin under vacuum, and emergency shutdown procedures consistent with OSHA 29 CFR 1910 Subpart Z chemical-hazard requirements and ACMA CCT safety competencies.
| # | Lesson | Hr | Type | Objective | Activities | Materials | Check |
|---|---|---|---|---|---|---|---|
| 1 | Infusion Process Theory and Closed-Mold Fundamentals | 10 | theory | Students will be able to explain Darcy's Law as it applies to resin flow through a fiber preform, describe the role of vacuum pressure in driving resin, and compare VARI to VARTM and hand layup in terms of fiber volume fraction and VOC reduction. |
| Whiteboard, ACMA Composites Industry Alliance training materials, ABYC Standards and Technical Information Reports for Small Craft (composite laminate sections), engineering calculator, blank infusion-stack labeling worksheets | Five-question short-answer quiz on Darcy's Law, pressure differential, fiber volume fraction calculation, and VARI vs. hand-layup VOC comparison; 80% correct required to proceed. |
| 2 | Chemical Hazards, PPE, and Ventilation for Infusion Resins | 10 | theory | Students will identify the specific health hazards of infusion-grade vinyl ester and epoxy resin systems, select correct PPE for each, and demonstrate compliance with OSHA Hazard Communication requirements including SDS interpretation. |
| Printed SDS packets (vinyl ester, epoxy, MEKP), half-face respirators with OV/P100 cartridges, nitrile gloves, chemical splash goggles, face shields, PPE log forms, OSHA Hazard Communication standard reference (29 CFR 1910.1200) | PPE donning observed by instructor using a five-point checklist (respirator, gloves, eye protection, skin coverage, decontamination sequence); all five points must be performed correctly before the student is cleared for lab work. ACMA CCT safety domain mapped here. |
| 3 | Tooling, Consumables, and Infusion Stack Setup | 15 | demo | Students will correctly identify each consumable layer in an infusion stack by function and install a complete stack — release coat, peel ply, reinforcement, flow media, spiral wrap feed lines, vacuum bag film, and sealant tape — on a flat demonstration mold with no missed steps. |
| Waxed aluminum or fiberglass flat molds, peel ply (nylon), flow media (biaxial mesh), spiral wrap tubing, vacuum bag film, sealant (tacky) tape, T-fittings, vacuum gauge, rotary vane vacuum pump, laminate schedule cards, resin TDS for vacuum-level specification | Instructor uses a six-point stack-setup checklist; all six points must be correct (layer sequence, sealant tape continuity, line placement, gauge connection, target vacuum achieved and held within allowable drop rate). Students who fail one or more points re-setup before advancing. ACMA CCT closed-mold process domain mapped here. |
| 4 | Resin Feed Network Design and Infusion Front Control | 12 | lab | Students will design a resin-feed and vacuum-line layout for a given panel geometry that produces an even infusion front, execute the infusion, and demonstrate front progression from feed to vacuum line without dry spots or race-tracking. |
| Scaled panel-geometry drawings, clear acrylic mold backing for dye test, water-soluble dye, biaxial fiberglass reinforcement (0/90 and ±45), infusion vinyl ester resin, MEKP catalyst, graduated mixing containers, digital scale, digital timer, vacuum pump, spiral wrap, flow media, peel ply, vacuum bag consumables, personal protective equipment | Dye-test photographs reviewed by instructor; front must be within 15% symmetry tolerance for the panel geometry. Production panel is post-cured and cross-sectioned at one corner; instructor inspects for dry spots, gross voids, or resin-starved areas using a 10× loupe. Pass = no dry spots larger than 6 mm and no race-tracking channels visible. ABYC composite laminate quality standard referenced. |
| 5 | Resin Mixing, Pot Life, and Process Documentation | 10 | lab | Students will mix an infusion resin system to the manufacturer's specified ratio, calculate available infusion time from pot-life data at ambient temperature, record a complete batch record, and complete an infusion within the pot-life window. |
| Infusion vinyl ester resin (or epoxy for epoxy-infusion station), MEKP catalyst (or appropriate epoxy hardener), digital scale (0.1 g resolution), disposable mixing containers, wooden stir sticks, digital thermometer, sling psychrometer or digital hygrometer, batch-record forms, stopwatch, PPE | Batch-record form reviewed by instructor for completeness (resin type, lot number, catalyst weight, percentage, shop temp, humidity, mix start time, infusion start time, front arrival time); all fields must be filled. Calculated pot-life utilization must be ≤ 80% of TDS-stated gel time. 100% completion of form required to pass. ACMA CCT process-documentation domain mapped here. |
| 6 | Defect Recognition, Troubleshooting, and Quality Inspection | 15 | practice | Students will identify the five primary vacuum-infusion defects — bag leak, dry spot, race-tracking, bridging, and resin starvation — from cured laminate specimens and video case studies, state the cause of each, and describe the corrective action. |
| Defect laminate specimen set (six panels), tap-test mallet (coin or small brass hammer), 10× loupe, defect log sheets, nonconformance report forms, vacuum-infusion demonstration setup, sealant tape, vacuum gauge, root-cause analysis worksheets, projector for video playback | Defect log sheet scored by instructor; students must correctly identify defect type and primary cause for at least five of six specimens and specify an appropriate corrective action for each. Pass = 5/6 correct identifications with viable corrective action stated. ACMA CCT quality-inspection domain and ABYC composite repair/inspection domain mapped here. |
| 7 | Integrated Infusion Build: Marine Hull Panel with Full Documentation | 15 | lab | Each student will independently execute a complete vacuum infusion of a curved marine structural panel — from mold prep through post-cure and final quality inspection — producing a batch record, process log, and a written summary that meets industry traceability requirements. |
| Curved mold (instructor-provided, representing a hull section), specified fiberglass reinforcement (biaxial and woven roving per laminate schedule), structural core material (PVC foam or balsa), infusion vinyl ester resin, MEKP, full infusion consumable set, digital scale, thermometer, hygrometer, batch-record and process-log forms, nonconformance report form, tap-test mallet, 10× loupe, PPE, trimming tools (pneumatic cutter or oscillating saw, hearing protection) | Instructor evaluates finished panel against a five-criterion rubric: (1) vacuum integrity achieved before infusion, (2) batch record complete and gel-time utilization ≤ 80%, (3) no dry spots > 6 mm on visual and tap-test inspection, (4) process log fully completed with timestamps and photos, (5) written summary includes all required fields. Pass = 4 of 5 criteria met at acceptable standard; criterion 1 (vacuum integrity) is mandatory — a part infused without a passing integrity test scores zero. ACMA CCT and ABYC composite domain competencies mapped here. |
| Assessment | Type | Weight | Pass standard | Method & rubric |
|---|---|---|---|---|
| Vacuum Infusion Written Knowledge Exam | Written exam | 25% | 75% or higher (30 of 40 questions correct) | A 40-question closed-book multiple-choice and short-answer exam covering Darcy's Law and resin-flow theory, infusion-stack layer sequence and function, resin-to-catalyst ratios and pot-life calculations, vacuum-integrity test criteria, defect identification and root causes, and chemical-hazard and SDS interpretation. Questions are mapped to ACMA CCT closed-mold-process and safety knowledge domains and to ABYC composite laminate content areas. Standard met · Safety · Time · Quality/finish · Documentation |
| Infusion Skills Demonstration | Skills demonstration | 45% | Pass all five mandatory checkpoints; no checkpoint may be skipped or waived | The student performs a complete vacuum infusion of an instructor-specified panel in real time while the instructor evaluates five checkpoints using a signed skills checklist: (1) correct PPE donned before resin contact, (2) complete infusion stack installed in correct layer order, (3) vacuum integrity test passed before resin introduction, (4) batch record completed with all required fields before resin pot is opened, (5) infusion front reaches vacuum line without dry spots and resin pot is closed within pot-life window. This demonstration is directly aligned to ACMA CCT closed-mold-process performance criteria. Standard met · Safety · Time · Quality/finish · Documentation |
| Lab Process Log Portfolio | Log | 15% | All seven lesson lab logs submitted; average score of 80% across the scoring rubric | Students maintain a running lab log begun in Lesson 3 and completed through Lesson 7, containing batch records, vacuum-gauge readings, infusion timestamps, defect-log sheets, nonconformance reports, and process photos for every hands-on session. The instructor scores each entry on completeness, accuracy of recorded data, and clarity of the written observations using a four-point rubric per entry; the portfolio demonstrates the process-documentation discipline required for production traceability under ACMA CCT and marine-industry quality-management expectations. Standard met · Safety · Time · Quality/finish · Documentation |
| Chemical Safety and PPE Compliance Check | Safety audit | 15% | All six checklist items correct; any single failure requires immediate remediation and re-check before the student may continue lab work | A proctored, unannounced observation conducted by the instructor during one of the resin-mixing or infusion sessions in Lessons 4–7; the instructor verifies six items: (1) correct respirator with appropriate cartridges donned and fit-checked, (2) chemical-splash goggles or face shield worn during resin handling, (3) nitrile gloves of appropriate thickness worn throughout resin contact, (4) skin coverage meeting SDS requirements, (5) student can state the location of the SDS for the resin system in use, (6) student can demonstrate the emergency eyewash station activation procedure. This check maps directly to OSHA 29 CFR 1910.1200 Hazard Communication requirements and to the ACMA CCT safety-compliance domain. Standard met · Safety · Time · Quality/finish · Documentation |
MFG-COMP18-05 Trade course
Gelcoat: Application, Color Matching, and Surface Finishing
87 hr · $1,305 COMPLIMENTARY
Students learn the chemistry, mixing, application, and finishing of polyester and vinyl ester gelcoat as used in production and custom boatbuilding. Emphasis is placed on achieving a Class A surface, accurate color matching, and minimizing common defects such as pinholes, fisheyes, and runs. Lessons align to ABYC Composite Boat Builder and ACMA CCT exam competency areas covering surface preparation, coating application, and quality control.
Outcomes- Mix gelcoat to correct resin-to-MEKP catalyst ratios and verify pot life using manufacturer technical data sheets.
- Apply gelcoat by spray gun and brush/roller to achieve uniform film thickness within the specified range, confirmed by wet-film gauge measurement.
- Diagnose and correct at least six common gelcoat defects (pinholes, crazing, fisheyes, runs, porosity, and color variation) using standard corrective procedures.
- Perform a multi-step color match—including tinting, drawdown comparison, and spectrophotometer-assisted verification—that achieves an acceptable visual and measured match.
- Execute a complete surface finishing sequence (block sanding through compound and polish) producing a surface free of visible scratches at final grit.
- Follow all OSHA respiratory, skin, and fire-prevention requirements for styrene- and MEKP-containing materials, correctly selecting and donning required PPE.
Course text
Students learn the chemistry, mixing, application, and finishing of polyester and vinyl ester gelcoat as used in production and custom boatbuilding. Emphasis is placed on achieving a Class A surface, accurate color matching, and minimizing common defects such as pinholes, fisheyes, and runs. Lessons align to ABYC Composite Boat Builder and ACMA CCT exam competency areas covering surface preparation, coating application, and quality control.
How the course runs. 7 blocks: Gelcoat Chemistry, Safety, and Material Selection; Catalyst Ratio, Pot Life, and Mixing Procedures; Spray Application: Equipment Setup, Technique, and Film Build; Brush-and-Roll Application and Tooling Gelcoat; Color Matching and Tinting; Surface Finishing: Sanding, Compounding, and Polishing; Defect Diagnosis, Quality Control Inspection, and Documentation.
What competent looks like. Mix gelcoat to correct resin-to-MEKP catalyst ratios and verify pot life using manufacturer technical data sheets. Apply gelcoat by spray gun and brush/roller to achieve uniform film thickness within the specified range, confirmed by wet-film gauge measurement. Diagnose and correct at least six common gelcoat defects (pinholes, crazing, fisheyes, runs, porosity, and color variation) using standard corrective procedures. Perform a multi-step color match—including tinting, drawdown comparison, and spectrophotometer-assisted verification—that achieves an acceptable visual and measured match. Execute a complete surface finishing sequence (block sanding through compound and polish) producing a surface free of visible scratches at final grit. Follow all OSHA respiratory, skin, and fire-prevention requirements for styrene- and MEKP-containing materials, correctly selecting and donning required PPE.
| # | Lesson | Hr | Type | Objective | Activities | Materials | Check |
|---|---|---|---|---|---|---|---|
| 1 | Gelcoat Chemistry, Safety, and Material Selection | 10 | theory | Students will identify the chemical composition of orthophthalic, isophthalic, and vinyl ester gelcoats, explain the peroxide-catalyzed cure mechanism, and state all OSHA and NFPA hazard controls required before handling. |
| Manufacturer TDS and SDS documents for at least three gelcoat products, OSHA 29 CFR 1910.94 ventilation standard, NFPA 30 flammable-liquids reference, trade notebook, whiteboard. | Short written quiz (10 questions, multiple-choice and short-answer) on gelcoat chemistry, cure mechanism, and required PPE/engineering controls; passing score 75%. |
| 2 | Catalyst Ratio, Pot Life, and Mixing Procedures | 12 | theory | Students will accurately measure and mix gelcoat to manufacturer-specified catalyst ratios, confirm correct gel time with a stopwatch, and document results against TDS specifications. |
| Production gelcoat (white and gray), MEKP catalyst, digital gram scale, graduated cylinders, stopwatch, thermometer, wet-film gauge, mixing sticks, metal waste containers, water, mixing log forms, full PPE kit (nitrile gloves, face shield, chemical splash goggles, half-mask respirator with organic-vapor/P100 cartridges, Tyvek sleeves). | Instructor reviews each student's three mixing logs; gel times must fall within ±2 minutes of TDS prediction at ambient temperature; no batch with ratio outside manufacturer limits accepted. Pass = 100% of batches logged correctly with compliant ratios. |
| 3 | Spray Application: Equipment Setup, Technique, and Film Build | 18 | lab | Students will set up and operate a pressure-pot or HVLP gelcoat spray system, apply gelcoat to a test panel in two cross-coat passes, and achieve a uniform wet-film thickness in the range specified by the manufacturer. |
| Pressure-pot spray system or HVLP gun with appropriate fluid tip, gelcoat (white, production grade), MEKP catalyst, wet-film gauge, waxed aluminum test panels (12×18 in.), mold release (carnauba or PVA), kraft paper, air-pressure gauge, fluid-pressure gauge, solvent for cleanup (acetone), PPE as above, ventilated spray booth with explosion-proof fan. | Instructor measures five random wet-film readings per panel with a calibrated wet-film gauge; all five must fall within manufacturer target range (typically 18–24 mils wet, verify against TDS). Zero runs or sags accepted. Pass = all five readings in range, no uncorrected defects. Rubric score 75% or higher required. |
| 4 | Brush-and-Roll Application and Tooling Gelcoat | 8 | practice | Students will apply tooling gelcoat and cosmetic gelcoat by brush and foam roller to a mold surface and an open-mold laminate, achieving a void-free, even film without introducing contamination. |
| Tooling gelcoat, cosmetic white gelcoat, MEKP, natural-bristle 2-inch brushes, 4-inch foam rollers, small fiberglass mold (pre-made by program), mold release wax, clean lint-free rags, acetone, magnifying loupe, raking-light fixture, defect-log forms, PPE. | Instructor inspects cured panel under raking light; panel must show no unfilled pinholes and even color coverage with no dry or thin spots visible; defect log completed with corrective actions noted. Pass = zero unfilled pinholes, log complete. |
| 5 | Color Matching and Tinting | 14 | lab | Students will tint a base gelcoat to match a provided production color chip using colorimetric paste additions, confirm match by drawdown card comparison and spectrophotometer reading, and document the formula. |
| White production gelcoat, universal gelcoat tinting pastes (yellow, red, blue, black, raw umber at minimum), MEKP, drawdown cards (sealed white card stock), drawdown bar or tongue depressor, daylight-balanced light box, bench spectrophotometer or calibrated color meter, digital gram scale, color-formula cards, PPE. | Final cured drawdown card is placed beside the target chip in the light box and evaluated by instructor; ΔE ≤ 3.0 (or a visually acceptable match if spectrophotometer not available, confirmed by two instructors independently). Color formula card must be complete and reproducible. Pass = ΔE ≤ 3.0 or dual-instructor visual pass, plus complete formula card. |
| 6 | Surface Finishing: Sanding, Compounding, and Polishing | 15 | lab | Students will execute a full multi-stage hand and machine finishing sequence on a cured gelcoat panel, progressing from block sanding through final machine polish to produce a defect-free, high-gloss surface. |
| Cured gelcoat test panels (from previous lessons or purpose-sprayed), wet-dry sandpaper (220–2000 grit), hard rubber sanding block, spray bottle with water, dual-action orbital polisher, foam cutting and finishing pads, marine rubbing compound, finishing polish, carnauba or polymer wax, clean microfiber cloths, gloss meter, raking-light fixture, lab log forms, safety glasses, nitrile gloves, hearing protection. | Instructor measures gloss with a calibrated gloss meter; 60° gloss reading must be ≥ 85 GU (gloss units) on a production-color panel, with no visible scratches under raking light at arm's length. Lab log entries complete for each sanding step. Pass = ≥ 85 GU at 60°, no visible scratches, complete log. |
| 7 | Defect Diagnosis, Quality Control Inspection, and Documentation | 10 | theory | Students will identify, diagnose root causes for, and prescribe corrective actions for a range of intentionally produced gelcoat defects on a set of sample panels, then complete a quality-control inspection report to industry standards. |
| Defect-library sample panels (pre-made), defect-identification worksheets, six station cards with unknown-defect panels, inspection forms, QC report forms (modeled on ABYC/ACMA documentation examples), raking-light fixture, gloss meter, magnifying loupe, pens. | Students must correctly identify, diagnose, and prescribe corrective actions for at least 5 of 6 unknown-defect stations (83% accuracy); QC report must be fully completed with accurate gloss-meter data and signed. Pass = ≥ 83% defect-station accuracy, complete and accurate QC report. |
| Assessment | Type | Weight | Pass standard | Method & rubric |
|---|---|---|---|---|
| Gelcoat Theory Knowledge Exam | Written exam | 25% | 75% correct (38 of 50 questions) | A 50-question closed-book written exam covering gelcoat chemistry and types, catalyst ratios and pot life, hazard controls and PPE selection, spray-equipment setup, defect identification, color theory, and QC documentation; questions are in multiple-choice and short-answer format aligned to ABYC Composite Boat Builder and ACMA CCT knowledge domains. Standard met · Safety · Time · Quality/finish · Documentation |
| Spray Application Skills Demonstration | Skills demonstration | 45% | All critical items scored; rubric score ≥ 75%; zero safety violations | Students set up a spray system from scratch, mix a catalyzed batch within the allowable ratio range, and spray a 12-by-18-inch test panel in two cross-coat passes; an instructor scores setup, mixing documentation, spray technique, and film-build uniformity using a standardized rubric, with wet-film gauge verification of all five checkpoints falling within the manufacturer's target range. Standard met · Safety · Time · Quality/finish · Documentation |
| Lab Log Portfolio | Log | 15% | All seven lesson lab logs submitted; average score ≥ 75% across portfolio rubric | Students submit a complete portfolio of mixing logs, defect logs, color-formula cards, sanding-sequence records, gloss-meter data sheets, and QC inspection reports collected across all seven lessons; entries are scored for accuracy, completeness, and correct unit notation, and the portfolio is reviewed as evidence of consistent documentation habits expected on a production floor. Standard met · Safety · Time · Quality/finish · Documentation |
| PPE and Hazard-Communication Safety Check | Safety audit | 15% | 100% on all critical PPE and hazard-communication items; no attempt with missing critical PPE | Before any spray session, an instructor conducts an unannounced verification using a binary (pass/fail per item) checklist confirming: correct respirator cartridge type and seal check performed, chemical-splash goggles worn, nitrile gloves of adequate thickness, no open flames or ignition sources present, SDS located and accessible, and catalyzed waste disposal container in place; a single critical failure stops the session and requires a re-check on a subsequent day. Standard met · Safety · Time · Quality/finish · Documentation |
MFG-COMP18-06 Trade course
Fiberglass & Composites Repair
87 hr · $1,305 COMPLIMENTARY
Students develop hands-on competency in diagnosing, preparing, and executing structural and cosmetic repairs to fiberglass and composite boat hulls, decks, and components using industry-standard laminating, fairing, and gelcoat techniques. The course covers damage assessment, substrate preparation, core replacement, wet layup and vacuum-bagged patch repairs, and finish restoration aligned with ABYC and ACMA CCT standards. Emphasis is placed on safe chemical handling, surface quality that meets production tolerances, and documentation practices required in professional repair facilities.
Outcomes- Diagnose fiberglass and composite damage types—including delamination, osmotic blistering, core rot, impact fractures, and gelcoat crazing—using visual inspection, tap testing, and moisture meters, and document findings in a written damage report.
- Prepare damaged substrates by grinding, beveling, and scarfing to the correct taper ratio for structural laminate patches, following manufacturer data sheets and ABYC composite repair guidance.
- Fabricate and cure wet-layup and vacuum-bagged laminate repairs using polyester, vinyl ester, and epoxy resin systems, achieving void-free bonds with lap-shear strength meeting design specifications.
- Replace deteriorated balsa and foam core sections in deck and hull panels, bonding new core material and restoring the sandwich laminate schedule to match the original construction.
- Apply, fair, and finish gelcoat repairs and topcoat patches that blend with surrounding surfaces to within accepted color and gloss tolerances, using proper catalyzation, spray or brush application, and wet-sanding/buffing sequences.
- Work throughout all repair tasks in compliance with OSHA Hazard Communication, respiratory protection, and lockout/tagout requirements, and record all safety and quality steps in a lab log suitable for professional shop documentation.
Course text
Students develop hands-on competency in diagnosing, preparing, and executing structural and cosmetic repairs to fiberglass and composite boat hulls, decks, and components using industry-standard laminating, fairing, and gelcoat techniques. The course covers damage assessment, substrate preparation, core replacement, wet layup and vacuum-bagged patch repairs, and finish restoration aligned with ABYC and ACMA CCT standards. Emphasis is placed on safe chemical handling, surface quality that meets production tolerances, and documentation practices required in professional repair facilities.
How the course runs. 7 blocks: Damage Assessment and Repair Planning; Surface Preparation: Grinding, Tapering, and Scarfing; Laminate Patch Repair: Wet Layup and Vacuum Bagging; Core Replacement in Sandwich Panels; Osmotic Blister Treatment and Barrier Coat Application; Cosmetic Repair: Gelcoat Patching, Fairing, and Polishing; Shop Safety, Hazard Communication, and Repair Documentation.
What competent looks like. Diagnose fiberglass and composite damage types—including delamination, osmotic blistering, core rot, impact fractures, and gelcoat crazing—using visual inspection, tap testing, and moisture meters, and document findings in a written damage report. Prepare damaged substrates by grinding, beveling, and scarfing to the correct taper ratio for structural laminate patches, following manufacturer data sheets and ABYC composite repair guidance. Fabricate and cure wet-layup and vacuum-bagged laminate repairs using polyester, vinyl ester, and epoxy resin systems, achieving void-free bonds with lap-shear strength meeting design specifications. Replace deteriorated balsa and foam core sections in deck and hull panels, bonding new core material and restoring the sandwich laminate schedule to match the original construction. Apply, fair, and finish gelcoat repairs and topcoat patches that blend with surrounding surfaces to within accepted color and gloss tolerances, using proper catalyzation, spray or brush application, and wet-sanding/buffing sequences. Work throughout all repair tasks in compliance with OSHA Hazard Communication, respiratory protection, and lockout/tagout requirements, and record all safety and quality steps in a lab log suitable for professional shop documentation.
| # | Lesson | Hr | Type | Objective | Activities | Materials | Check |
|---|---|---|---|---|---|---|---|
| 1 | Damage Assessment and Repair Planning | 10 | theory | Students will correctly identify and categorize at least five classes of fiberglass and composite damage and produce a written repair plan that specifies materials, laminate schedule, and sequence of operations. |
| Moisture meters (pin-type and pinless), rubber tap-testing mallets, sample fiberglass panels with seeded defects, ABYC Composite Boat Builder study guide, ACMA CCT reference manual, manufacturer technical data sheets (TDS) for polyester, vinyl ester, and epoxy systems, whiteboard, projector | Students submit a written repair plan for one assigned scenario; instructor scores against a rubric covering correct damage classification, appropriate resin system choice, correct laminate schedule, and safety notes—minimum passing score 75%. |
| 2 | Surface Preparation: Grinding, Tapering, and Scarfing | 14 | lab | Students will prepare a damaged fiberglass panel for structural repair by grinding to bright laminate, cutting a correctly tapered scarf at the specified ratio, and verifying geometry with straightedge and calipers before any resin is mixed. |
| Angle grinders (4.5-inch), grinding discs (36, 60, 80 grit), die grinders with carbide burrs, digital calipers, straightedges, chalk line, P100 half-face respirators, face shields, safety glasses, nitrile and leather gloves, Tyvek coveralls, hearing protection, vacuum shrouds or local exhaust ventilation, damaged fiberglass panel sections (hull offcuts), lab log notebooks | Instructor measures three points along the taper with calipers; taper ratio must be between 11:1 and 13:1, surface must be free of shiny resin and delaminated plies as confirmed by tap test—pass requires all three measurements within tolerance and a clean tap-test result. |
| 3 | Laminate Patch Repair: Wet Layup and Vacuum Bagging | 18 | lab | Students will fabricate a multi-ply fiberglass laminate patch repair using both wet layup and vacuum-bagged methods, achieving a cured patch that is void-free on destructive cross-section inspection and meets the original laminate thickness within ±10%. |
| Polyester, vinyl ester, and epoxy resin kits with hardeners/catalysts, woven roving, biaxial and chopped-strand mat (CSM), peel ply, perforated release film, bleeder/breather cloth, bagging film, sealant tape, vacuum pump, vacuum gauge, grooved aluminum rollers, plastic squeegees, mixing cups and sticks, gram scale, diamond-blade wet saw, digital calipers, 10× loupes, solvent (acetone), PPE as in Lesson 2, ACMA CCT reference manual | Cross-section coupon shows no voids larger than 1 mm visible at 10× magnification; cured thickness is within ±10% of the target from the repair plan; lab log entry is complete with resin mix ratios, pot life, vacuum readings, and cure time—all three criteria must be met to pass. |
| 4 | Core Replacement in Sandwich Panels | 14 | lab | Students will remove deteriorated balsa or foam core from a pre-damaged sandwich panel section, install and bond new core material, restore the inner skin laminate, and verify bond quality by tap test before final inspection. |
| Pre-damaged sandwich panels with balsa and foam core, oscillating multi-tool, router with depth stop, chisels, scrapers, heat gun, end-grain balsa sheets, closed-cell PVC foam (Divinycell or equivalent), epoxy adhesive kits, colloidal silica and low-density fillers, gram scale, mixing cups, brushes, peel ply, sandbag weights, vacuum equipment (optional), tap-testing mallets, digital calipers, PPE as in Lesson 2, ABYC composite repair reference | Post-cure tap test of the entire repaired zone produces a solid ring throughout with no hollow areas; core-to-skin bond line is visible and continuous on at least one cross-section coupon taken from the panel edge—pass requires passing tap test AND visible continuous bond line. |
| 5 | Osmotic Blister Treatment and Barrier Coat Application | 10 | demo | Students will describe the chemistry of osmotic blistering, correctly execute the blister-opening, washing, drying, and epoxy barrier coat application sequence on a prepared hull section, and explain why each step is necessary. |
| Blister-seeded fiberglass panels, angle grinders, pH test strips, clean water and brushes for flushing, two-part epoxy barrier coat system, foam rollers and brush applicators, wet-film thickness gauges, mixing cups and sticks, gram scale, heat lamp or dehumidifier for drying demonstration, pH meter (optional), PPE as in Lesson 2, manufacturer TDS for barrier coat product | Students answer five comprehension questions with a minimum score of 80%; wet-film gauge readings on both coats are within the TDS target range (±15%); lab log entry documents pH readings, drying time, and application steps—all three criteria must pass. |
| 6 | Cosmetic Repair: Gelcoat Patching, Fairing, and Polishing | 14 | lab | Students will apply a catalyzed gelcoat patch to a repaired panel, fair the surface with filler and sandpaper progression, and wet-sand and buff to a gloss reading within 15 gloss units of the surrounding original surface as measured by a gloss meter. |
| Gelcoat (pigmented polyester or vinyl ester), MEKP catalyst, color tint pastes, wax surface agent (PVA or styrene wax), brushes, mixing cups and sticks, gram scale, sandpaper in grits 80–2000, hard backing blocks, guide coat aerosol, 60° gloss meter, dual-action orbital polisher, polishing compound, finishing glaze, polishing pads, PPE including nitrile gloves, safety glasses, respirator for styrene vapor (organic-vapor cartridge), ACMA CCT reference | Gloss meter reading at all five measurement points is within 15 gloss units of the adjacent original surface; surface is flat across a 12-inch straightedge with no visible low spots when a guide coat is applied—both criteria must be met to pass. |
| 7 | Shop Safety, Hazard Communication, and Repair Documentation | 7 | theory | Students will locate and correctly interpret Safety Data Sheets for all resins and solvents used in the course, demonstrate a lockout/tagout procedure on shop equipment, and assemble a complete professional repair documentation package for a previous lab repair. |
| SDS binders for all course chemicals (polyester, vinyl ester, epoxy, MEKP, acetone, gelcoat, barrier coat), OSHA Hazard Communication standard reference (29 CFR 1910.1200), lockout/tagout devices (padlocks, hasps, tags), repair order template, peer-review checklist, computers or tablets for online SDS lookup, ABYC Composite Boat Builder study guide | SDS worksheet is scored against answer key—minimum 80% correct; LOTO demonstration is evaluated pass/fail by instructor (pass requires all energy isolation steps in correct order with no prompting); documentation package is scored against checklist—minimum 75% of required items present and accurate—all three sub-checks must pass. |
| Assessment | Type | Weight | Pass standard | Method & rubric |
|---|---|---|---|---|
| Repair Theory Knowledge Exam | Written exam | 25% | Minimum score of 75% (38 out of 50 questions correct) | A 50-question written exam covering damage diagnosis, resin system chemistry, laminate schedule selection, core repair theory, osmotic blister treatment, gelcoat catalyzation, and OSHA hazard communication, mapped to ABYC Composite Boat Builder and ACMA CCT exam content areas. Questions are multiple choice and short answer; students have 90 minutes to complete the exam. Standard met · Safety · Time · Quality/finish · Documentation |
| Structural Patch Repair Skills Demonstration | Skills demonstration | 45% | All four rubric categories scored at least 2 out of 3; no category scored 0 | Each student independently repairs an instructor-assigned damaged fiberglass panel from scratch—assessing damage, preparing the substrate, laminating a vacuum-bagged patch, and finishing with gelcoat—while an instructor evaluates using a four-category rubric: surface preparation quality, laminate void content (cross-section inspection), dimensional accuracy of patch thickness, and gelcoat gloss match. The demonstration is completed within one scheduled lab session. Standard met · Safety · Time · Quality/finish · Documentation |
| Repair Lab Log Portfolio | Log | 15% | Minimum 75% of required entries present, complete, and accurate as scored on the portfolio rubric | Students submit their cumulative lab log from all seven lessons, which must include dated entries for every lab exercise containing: damage classification notes, repair plans, resin mix ratios and pot-life records, vacuum gauge readings, tap-test results, thickness measurements, gloss meter readings, and SDS references for every chemical used. Completeness, accuracy, and professional legibility are scored against a published rubric. Standard met · Safety · Time · Quality/finish · Documentation |
| Safety Compliance Check | Safety audit | 15% | Pass/Fail — all critical items must be satisfactory; any single critical failure results in immediate remediation before the student may continue | An unannounced or scheduled 15-minute observation in which the instructor evaluates each student against a safety checklist covering: correct PPE selection and donning for the task in progress, proper chemical storage and labeling, accurate SDS location within 60 seconds, and correct execution of the lockout/tagout procedure on one designated piece of equipment. Critical items include respiratory protection selection and LOTO steps; all critical items must be performed correctly without prompting to pass. Standard met · Safety · Time · Quality/finish · Documentation |
MFG-COMP18-07 Capstone
Capstone Project: Integrated Composite Boat Component Build
108 hr · $1,080 COMPLIMENTARY
Students plan, fabricate, finish, and document a full-scale composite boat component or small vessel subassembly—such as a hatch, console panel, or hull section—using mold preparation, hand layup or vacuum infusion, gelcoat finishing, and repair techniques learned across the program. The capstone integrates trade math, material selection, quality inspection, and safety compliance into one documented build sequence culminating in a formal oral defense before an industry evaluator. Lesson work is mapped to ABYC Composite Boat Builder and ACMA Certified Composites Technician (CCT) exam domains including process knowledge, materials identification, quality control, and safety.
Outcomes- Develop and execute a written build plan for a composite boat component that specifies materials, layup schedule, cure parameters, and quality hold points consistent with ABYC and ACMA standards.
- Fabricate a structurally sound composite part using at least two processes (e.g., wet layup and vacuum bag or infusion) and demonstrate correct fiber orientation, resin-to-glass ratio, and void-free consolidation.
- Apply gelcoat and finish the part to a surface quality acceptable for marine service, measured against industry color and gloss standards.
- Inspect the finished part using visual, tap-test, and template methods; document any defects and execute and record a repair that restores structural and cosmetic integrity.
- Assemble a project portfolio that includes a build plan, material safety data sheets (SDS), inspection records, photographic log, and a completed quality-control checklist traceable to ABYC and ACMA exam content areas.
- Present and defend the completed project and portfolio before an evaluator, demonstrating the ability to explain process decisions, safety measures, and quality outcomes in trade-appropriate language.
Course text
Students plan, fabricate, finish, and document a full-scale composite boat component or small vessel subassembly—such as a hatch, console panel, or hull section—using mold preparation, hand layup or vacuum infusion, gelcoat finishing, and repair techniques learned across the program. The capstone integrates trade math, material selection, quality inspection, and safety compliance into one documented build sequence culminating in a formal oral defense before an industry evaluator. Lesson work is mapped to ABYC Composite Boat Builder and ACMA Certified Composites Technician (CCT) exam domains including process knowledge, materials identification, quality control, and safety.
How the course runs. 4 blocks: Project Planning, Material Selection, and Build Documentation Setup; Mold Preparation, Layup, and Infusion Fabrication; Gelcoat Finishing, Defect Repair, and Final Inspection; Portfolio Completion and Project Defense.
What competent looks like. Develop and execute a written build plan for a composite boat component that specifies materials, layup schedule, cure parameters, and quality hold points consistent with ABYC and ACMA standards. Fabricate a structurally sound composite part using at least two processes (e.g., wet layup and vacuum bag or infusion) and demonstrate correct fiber orientation, resin-to-glass ratio, and void-free consolidation. Apply gelcoat and finish the part to a surface quality acceptable for marine service, measured against industry color and gloss standards. Inspect the finished part using visual, tap-test, and template methods; document any defects and execute and record a repair that restores structural and cosmetic integrity. Assemble a project portfolio that includes a build plan, material safety data sheets (SDS), inspection records, photographic log, and a completed quality-control checklist traceable to ABYC and ACMA exam content areas. Present and defend the completed project and portfolio before an evaluator, demonstrating the ability to explain process decisions, safety measures, and quality outcomes in trade-appropriate language.
| # | Lesson | Hr | Type | Objective | Activities | Materials | Check |
|---|---|---|---|---|---|---|---|
| 1 | Project Planning, Material Selection, and Build Documentation Setup | 20 | theory | Given a project brief for a specified marine composite component, the student will produce a complete written build plan that identifies materials, laminate schedule, process sequence, PPE and ventilation requirements, and quality hold points, with all entries traceable to SDS and relevant ABYC or ACMA reference material. |
| Project brief handout, ABYC Composite Boat Building reference manual, ACMA CCT candidate guide, SDS for polyester or vinyl ester resin, glass fabric, core material, gelcoat, and release agent; calculator, laminate-thickness worksheet, project binder, digital folder on shop computer or tablet, pen and highlighters | Instructor reviews each student's completed build plan against a 12-item rubric covering: bill of materials completeness, correct resin calculation (within 5% of instructor answer key), appropriate layup schedule, identified hold points, PPE and ventilation plan, and SDS inclusion. Passing standard: 10 of 12 items satisfactory; any safety-critical item (PPE, SDS, ventilation) missing requires revision before the student proceeds to fabrication. |
| 2 | Mold Preparation, Layup, and Infusion Fabrication | 48 | lab | Following the approved build plan, the student will prepare a mold, execute the laminate using at least two processes (wet hand layup and vacuum bag consolidation or resin infusion), and produce a cured part with no dry spots, no bridging at corners, and a fiber-to-resin ratio within the range specified in the build plan. |
| Plug or production mold (tool matched to project brief), mold release wax or semi-permanent release agent, gelcoat, 1.5-oz chopped-strand mat and woven roving or biaxial fabric per schedule, vinyl ester or polyester resin, MEKP catalyst, infusion resin if applicable, vacuum bag film, tacky tape, peel ply, flow media, infusion lines and fittings, vacuum pump, calibrated vacuum gauge, wet-film gauge, consolidation rollers, chip brushes, peel-ply burnishing tool, cutoff wheel, die grinder, half-face respirator with OV/P100 cartridges, nitrile gloves, Tyvek suit, safety glasses, hearing protection, tap-test coin, painter's tape, photographic log, project binder | Instructor performs a structured part inspection at demolding using a standardized inspection sheet: visual check for dry areas, bridging, and print-through; tap-test map recorded on a part outline sketch; cross-section measurement at three locations compared to the target thickness in the build plan (within ±10%); bag-log review confirming vacuum held within specification throughout infusion. Passing standard: zero untreated dry spots greater than 1 square inch, zero delaminated areas confirmed by tap test, thickness within tolerance at all three measurement points, and all hold points in the project binder signed off. Any failing item must be remediated or documented as a repair task in Lesson 3. |
| 3 | Gelcoat Finishing, Defect Repair, and Final Inspection | 28 | practice | The student will finish the cured composite part to a marine-grade surface quality by wet-sanding, compounding, and polishing gelcoat to a uniform gloss, identify and repair any structural or cosmetic defects using techniques from the Repair course, and complete a final inspection record that documents the part as acceptable or describes remaining limitations. |
| Wet-dry sandpaper in multiple grits, sanding blocks, flexible sanding pads, random-orbital polisher, compound, polish, microfiber cloths, gloss meter or reference panel, right-angle grinder with flap disc, die grinder, woven roving or biaxial fabric scraps, resin, MEKP catalyst, pigmented gelcoat paste, acetone for cleanup, half-face respirator with OV/P100 cartridges, nitrile gloves, safety glasses, hearing protection, repair log template, final inspection checklist, photographic log | Instructor and a second qualified evaluator (lead instructor or industry mentor) independently score the finished part using the same 15-item final inspection checklist covering surface gloss uniformity, absence of uncorrected dry spots or delaminations, edge finish, dimensional conformance, and repair quality. Passing standard: a score of 12 of 15 items rated acceptable by both evaluators, with zero safety-critical structural defects (untreated delaminations or exposed dry glass) remaining; any part failing the structural items must be remediated before the oral defense. |
| 4 | Portfolio Completion and Project Defense | 12 | field | The student will assemble and submit a complete project portfolio and present a 15-to-20-minute oral defense of the build process, quality decisions, and safety practices before an evaluator panel, answering questions drawn from ABYC Composite Boat Builder and ACMA CCT exam domains. |
| Completed project portfolio (binder and digital copy), finished composite part, laptop or tablet for digital display if needed, oral defense rubric, evaluator question bank drawn from ABYC and ACMA study guides, whiteboard or flip chart for sketching during responses | Portfolio scored against a 10-item submission checklist (all sections present and complete); oral defense scored by both evaluators using a shared rubric with four domains—technical accuracy, process rationale, safety knowledge, and professional communication—each rated on a 4-point scale (maximum 16 points). Passing standard: portfolio checklist complete (10 of 10 items), oral defense score of 12 of 16 with no domain rated 0; a student who does not pass on the first attempt may revise the portfolio or repeat the defense once within the course window. |
| Assessment | Type | Weight | Pass standard | Method & rubric |
|---|---|---|---|---|
| Finished Composite Part — Capstone Project Evaluation | Project | 60% | Score of 12 of 15 items rated acceptable on the final inspection checklist by two independent evaluators, with zero untreated structural defects remaining in the finished part. | Evaluators physically inspect the student's completed composite boat component against a standardized 15-item checklist covering laminate integrity (tap test and visual), gelcoat surface quality (gloss, color uniformity, absence of pinholes), edge and trim finish, dimensional conformance to the project brief, and the quality of any repairs performed. The part must meet marine-grade surface and structural standards consistent with ABYC composite boat building criteria. Meets specification · Within estimate · Workmanship · Safety · Documentation |
| Project Portfolio | Portfolio | 20% | All 10 required sections present and complete per the submission checklist, signed off by the instructor before the oral defense date. | The portfolio documents the full build cycle: approved build plan with laminate calculations, bill of materials, photographic log with captioned hold-point entries, SDS index for all chemicals used, signed quality-control and repair checklists, and a written reflection memo. It serves as evidence of the student's ability to plan, document, and critically evaluate a composite fabrication project in a format consistent with professional shop documentation practice. Completeness · Organization · Evidence quality |
| Oral Defense | Oral / panel | 20% | Score of 12 of 16 on the evaluator rubric with no domain rated 0, assessed by a panel of at least two evaluators. | In a 25-to-30-minute session, the student presents the project and answers evaluator questions drawn from ABYC Composite Boat Builder and ACMA CCT exam domains including materials identification, process knowledge, safety and health practices, and quality control. The rubric scores technical accuracy, process rationale, safety knowledge, and professional communication; written feedback is returned to the student within one class day and is used to guide study in the subsequent Certification Exam Preparation course. Explains decisions · Answers technical questions · Professional communication |
MFG-COMP18-08 Externship / clinical
Externship / Worksite Placement
162 hr · $650 COMPLIMENTARY
Students complete 162 supervised hours at a marine composites employer — a boatyard, production boat manufacturer, or composites repair shop — performing real production and repair tasks under a journeyman or lead technician. A credentialed site supervisor evaluates performance on safety practices, layup quality, vacuum infusion, gelcoat work, and professional conduct using a standardized employer rubric. This field experience bridges classroom skill and industry expectation, satisfying the applied-hours component recognized by ABYC and ACMA credentialing frameworks.
Outcomes- Perform assigned production or repair tasks — including wet layup, vacuum bagging, gelcoat application, or structural repair — to the quality standard accepted by the host employer without rework.
- Demonstrate consistent compliance with host-site safety rules, PPE requirements, and hazard communication protocols throughout all 162 worksite hours.
- Document daily work activities, materials used, and lessons learned in a professional externship log that meets program recordkeeping standards.
- Receive a passing employer evaluation score on all rated competency domains — safety, technical skill, communication, and professionalism — at the conclusion of the placement.
- Identify at least two ways the worksite's quality-control or inspection practices connect to ABYC or ACMA composites standards studied in the program.
- Reflect on career goals and next steps in a written exit report that references specific worksite experiences and industry credential pathways.
Course text
Students complete 162 supervised hours at a marine composites employer — a boatyard, production boat manufacturer, or composites repair shop — performing real production and repair tasks under a journeyman or lead technician. A credentialed site supervisor evaluates performance on safety practices, layup quality, vacuum infusion, gelcoat work, and professional conduct using a standardized employer rubric. This field experience bridges classroom skill and industry expectation, satisfying the applied-hours component recognized by ABYC and ACMA credentialing frameworks.
How the course runs. 4 blocks: Pre-Placement Orientation and Site Safety Briefing; Supervised Production Tasks — Weeks 1 through 3; Advanced Worksite Tasks and Independent Contribution — Weeks 4 through 6; Final Employer Evaluation, Exit Report, and Professional Debrief.
What competent looks like. Perform assigned production or repair tasks — including wet layup, vacuum bagging, gelcoat application, or structural repair — to the quality standard accepted by the host employer without rework. Demonstrate consistent compliance with host-site safety rules, PPE requirements, and hazard communication protocols throughout all 162 worksite hours. Document daily work activities, materials used, and lessons learned in a professional externship log that meets program recordkeeping standards. Receive a passing employer evaluation score on all rated competency domains — safety, technical skill, communication, and professionalism — at the conclusion of the placement. Identify at least two ways the worksite's quality-control or inspection practices connect to ABYC or ACMA composites standards studied in the program. Reflect on career goals and next steps in a written exit report that references specific worksite experiences and industry credential pathways.
| # | Lesson | Hr | Type | Objective | Activities | Materials | Check |
|---|---|---|---|---|---|---|---|
| 1 | Pre-Placement Orientation and Site Safety Briefing | 9 | field | Before the first production shift, the student will complete the host employer's site-specific safety orientation, review emergency procedures, and demonstrate correct PPE selection for the hazards present at that facility. |
| Host-employer safety orientation packet, SDS binder for resins and solvents on site, facility floor plan, blank site safety map template (program-supplied), PPE checklist form, OSHA Hazard Communication standard summary card. | Site supervisor confirms in writing on the program orientation sign-off form that the student can correctly name the PPE required for each assigned work area and has located all emergency resources; no unsupervised work begins until sign-off is complete — this is a binary pass/fail gate. |
| 2 | Supervised Production Tasks — Weeks 1 through 3 | 60 | lab | The student will complete assigned production or repair tasks — drawn from layup, infusion, gelcoat, trimming, or fitting — meeting the employer's acceptance criteria on at least 80 percent of evaluated work pieces during the first three weeks of placement. |
| Host employer's tools, molds, resin systems, reinforcement materials, and QC inspection gauges; program-supplied externship daily log forms; site supervisor mid-point feedback form; ABYC and ACMA composites standards summaries (student reference copies). | Site supervisor completes the program's mid-point rating form using a 4-point scale (1 = does not meet standard, 4 = exceeds standard) across five domains: safety compliance, technical execution, material handling, communication, and professionalism; student must average 2.5 or above across all domains to continue unsupervised on current task types — a score below 2.5 in any single domain triggers a documented remediation plan. |
| 3 | Advanced Worksite Tasks and Independent Contribution — Weeks 4 through 6 | 75 | field | The student will perform increasingly independent production or repair tasks, demonstrating reduced reliance on direct supervisor instruction and achieving the employer's first-pass quality acceptance rate on at least 85 percent of evaluated outputs during weeks 4 through 6. |
| Host employer's production tools and materials; vacuum infusion consumables as applicable; spray or brush gelcoat equipment; externship daily log forms; quality-reflection entry template (program-supplied); employer QC inspection records (reviewed on site, not removed). | Site supervisor records an informal daily acceptance / rework tally for the student's outputs; at the end of week 6, the coordinator or instructor reviews the tally — student must show an 85 percent or better first-pass acceptance rate on evaluated pieces; any week in which the rate falls below 70 percent triggers a same-week check-in between the student, supervisor, and program instructor. |
| 4 | Final Employer Evaluation, Exit Report, and Professional Debrief | 18 | theory | The student will submit a complete externship log, receive and discuss the final employer evaluation, and deliver a written exit report that connects specific worksite experiences to ABYC and ACMA credential competencies and to the student's near-term career plan. |
| Completed externship daily log binder; program summative employer evaluation rubric; exit report template with section prompts; ABYC Composite Boat Builder and ACMA CCT exam topic outlines (for cross-referencing); word processor or pen and lined paper. | Instructor scores the exit report on a 3-criterion rubric — accuracy and completeness of log (all shifts recorded with no blank required fields), quality of credential-to-practice connections (at least 2 specific and accurate references to ABYC or ACMA content areas), and clarity of career plan (concrete and actionable steps named) — each criterion scored 1–4; minimum passing score is 9 of 12; final employer evaluation must also show an overall average of 2.5 or higher on the summative rubric or the student does not pass the externship course. |
| Assessment | Type | Weight | Pass standard | Method & rubric |
|---|---|---|---|---|
| Summative Employer Skills Evaluation | Skills demonstration | 70% | Overall average of 2.5 or higher (on a 4-point scale) across all five domains — safety compliance, technical skill, material handling, communication, and professionalism — with no single domain rated below 2.0 on the final evaluation form. | The host-site supervisor completes the program's standardized summative evaluation rubric at the conclusion of the placement, rating the student across five workplace competency domains based on direct observation of performance over 162 hours. This skills demonstration assessment is the primary evidence that the student has met industry-level performance expectations in a live production or repair environment, connecting directly to the applied-competency requirements underlying both the ABYC Composite Boat Builder and ACMA CCT credentials. Competency · Safety · Attendance · Conduct · Initiative |
| Externship Log and Exit Report | Log | 30% | Combined rubric score of 9 out of 12 points (3 criteria, each scored 1–4): all required log entries complete and accurate, at least two specific and correct connections made between worksite practices and ABYC or ACMA exam content areas, and a concrete career action plan included in the exit report. | The student submits a complete shift-by-shift externship log covering all 162 placement hours, accompanied by a 600–900 word exit report that analyzes the experience through the lens of professional credentials and career development. The instructor evaluates both documents together as a lab-log assessment, confirming that the student can observe, record, and critically reflect on real trade work at the level expected by industry and by the credentialing bodies whose exams follow in Course 9. Complete · Verified |
MFG-COMP18-09 Exam prep
Certification Exam Preparation: ABYC Composite Boat Builder & ACMA CCT
45 hr · $450 COMPLIMENTARY
Students systematically review every domain tested on the ABYC Composite Boat Builder and ACMA Certified Composites Technician (CCT) exams, identify and close individual knowledge gaps, and sit timed, full-length mock exams under realistic testing conditions. Instruction is mapped directly to published exam content outlines for both credentials so no testable area is left unaddressed.
Outcomes- Demonstrate mastery of ABYC and ACMA CCT exam content domains — including materials science, laminate design, process methods, safety, and quality — by scoring at or above each credential's minimum passing standard on practice assessments.
- Apply trade mathematics (unit conversion, weight-per-area calculations, resin-to-reinforcement ratios, cure exotherm estimation) accurately and without aids, as required on closed-book exam sections.
- Interpret ABYC standards language, ACMA technical references, Safety Data Sheets, and laminate schedules to answer standards-based exam questions correctly.
- Execute a personal exam-readiness plan that schedules study sessions, targets weak domains identified through diagnostic scoring, and meets required credential application deadlines.
- Perform timed mock exams for both credentials, completing all items within the allotted time while maintaining accuracy consistent with a passing score.
- Explain the credential maintenance, recertification, and professional development requirements for both the ABYC Composite Boat Builder and ACMA CCT credentials.
Course text
Students systematically review every domain tested on the ABYC Composite Boat Builder and ACMA Certified Composites Technician (CCT) exams, identify and close individual knowledge gaps, and sit timed, full-length mock exams under realistic testing conditions. Instruction is mapped directly to published exam content outlines for both credentials so no testable area is left unaddressed.
How the course runs. 4 blocks: Diagnostic Assessment & Exam Blueprint Orientation; Domain Deep-Dive: Materials, Laminates, Processes & Standards; Applied Problem-Solving & Exam Strategy; Full Mock Certification Exams.
What competent looks like. Demonstrate mastery of ABYC and ACMA CCT exam content domains — including materials science, laminate design, process methods, safety, and quality — by scoring at or above each credential's minimum passing standard on practice assessments. Apply trade mathematics (unit conversion, weight-per-area calculations, resin-to-reinforcement ratios, cure exotherm estimation) accurately and without aids, as required on closed-book exam sections. Interpret ABYC standards language, ACMA technical references, Safety Data Sheets, and laminate schedules to answer standards-based exam questions correctly. Execute a personal exam-readiness plan that schedules study sessions, targets weak domains identified through diagnostic scoring, and meets required credential application deadlines. Perform timed mock exams for both credentials, completing all items within the allotted time while maintaining accuracy consistent with a passing score. Explain the credential maintenance, recertification, and professional development requirements for both the ABYC Composite Boat Builder and ACMA CCT credentials.
| # | Lesson | Hr | Type | Objective | Activities | Materials | Check |
|---|---|---|---|---|---|---|---|
| 1 | Diagnostic Assessment & Exam Blueprint Orientation | 8 | theory | Students will map their current knowledge against the published content domains of both the ABYC Composite Boat Builder and ACMA CCT exams and produce a written personal study plan that targets domains scored below passing. |
| Diagnostic practice-question bank (instructor-developed, aligned to published exam blueprints), ABYC Composite Boat Builder exam content outline (ABYC member resource), ACMA CCT Candidate Handbook, highlighters, two-column comparison worksheet, personal study plan template | Student submits a completed personal study plan with domain scores entered and at least three targeted remediation actions per weak domain; plan must be realistic and instructor-approved before Lesson 2 begins — pass = all required fields complete and instructor sign-off obtained. |
| 2 | Domain Deep-Dive: Materials, Laminates, Processes & Standards | 18 | theory | Students will correctly answer exam-style questions on composite materials properties, laminate design principles, wet layup and vacuum infusion processes, gelcoat application, and applicable ABYC standards by achieving at least 75 percent on domain quizzes administered at the end of each session. |
| ABYC standards library (school subscription), ACMA CCT Study Guide, manufacturer technical data sheets for common resin systems (epoxy, vinyl ester, polyester), SDS for styrene and common hardeners, laminate calculation worksheets, domain-quiz question bank, case-study defect photo sets, blank index cards for flashcards | Five domain quizzes of 20 questions each administered at the close of each major topic block; students must score at least 75 percent (15/20) on each quiz — any domain scored below 75 percent triggers a mandatory 30-minute targeted re-study session before the next lesson begins. |
| 3 | Applied Problem-Solving & Exam Strategy | 10 | demo | Students will apply elimination strategies, time-management techniques, and keyword recognition to correctly answer complex, scenario-based exam questions drawn from all domains at a rate consistent with each credential's passing standard within the allotted time per item. |
| Scenario-based question bank (instructor-developed), timer or stopwatch, ABYC Composite Boat Builder Candidate Handbook, ACMA CCT Candidate Handbook, application-readiness checklist, pencils, scratch paper | Students complete the 40-question timed drill and debrief form indicating questions flagged and final answers; instructor reviews pacing log — pass = student finishes all 40 items within the time window and scores at least 70 percent, demonstrating readiness for the full mock exam. |
| 4 | Full Mock Certification Exams | 9 | lab | Students will complete full-length, timed mock exams simulating both the ABYC Composite Boat Builder and ACMA CCT exams under closed-book, proctored conditions and achieve a score at or above each credential's published minimum passing standard. |
| ABYC mock exam question set (full length, proportional to published blueprint), ACMA CCT mock exam question set (full length, proportional to published blueprint), proctor sign-in sheet, timer, blank scratch paper, #2 pencils, individual score report template, domain-breakdown scoring rubric | Each student must achieve a score at or above the minimum passing standard published by ABYC for the Composite Boat Builder credential and at or above the minimum passing standard published by ACMA for the CCT credential on their respective mock exams — students who fall short on either mock exam receive a written remediation plan and a second mock sitting opportunity within the course hours remaining; readiness for live credentialing exam is confirmed in writing by instructor. |
| Assessment | Type | Weight | Pass standard | Method & rubric |
|---|---|---|---|---|
| Dual Credential Mock Examination Suite | Mock certification exam | 100% | Score at or above the minimum passing standard published in the current candidate handbook for each credential (ABYC Composite Boat Builder and ACMA CCT) on both full-length mock exams; students who pass both mocks receive instructor sign-off confirming exam readiness. | Students sit two full-length, proctored, closed-book mock exams — one aligned to the ABYC Composite Boat Builder content blueprint and one aligned to the ACMA CCT content blueprint — under timed testing conditions that replicate the actual credentialing experience. Scores are reported by domain so students and instructor can confirm readiness before the student schedules and sits the live credentialing exams. Score · Time management |
Program completion
External credential: ABYC Composite Boat Builder; ACMA CCT
Students sit the ABYC Composite Boat Builder examination administered by the American Boat and Yacht Council and the ACMA Certified Composites Technician (CCT) examination administered by the American Composites Manufacturers Association. Pass standard: Credential issued by the body.
Back to Fiberglass / Composites (boatbuilding) · How the school gets authority to award these credentials
