Advanced Composite Materials - Level 1
COURSE DESCRIPTION
This intensive 5-day course introduces students to the foundations of composite materials and their critical role in aerospace and other high-performance industries. Students explore fiber types such as carbon, glass, and aramid, along with fabric styles, weave patterns, and ply orientation concepts that influence strength and performance. The program covers resin systems and adhesives, emphasizing proper selection, storage, and surface preparation to ensure reliability. Through hands-on practice, participants gain experience with hand layup and vacuum bagging techniques, the use of tooling materials, and common repair methods including damage removal, core replacement, patching, drilling, fastening, and bonded repairs. Inspection and evaluation skills are built through exposure to visual and tap testing, resin-to-fiber ratio assessment, and an introduction to destructive and non-destructive inspection methods. Throughout the course, strong emphasis is placed on safety, proper use of PPE, and industry-standard handling of composite materials.
COURSE OBJECTIVES
Upon successful completion of this introductory course, students will be able to safely handle and process composite materials following industry best practices, while correctly identifying and using the terminology associated with composite materials, processes, and structural elements. They will understand and interpret basic composite design and ply orientation requirements and demonstrate core manufacturing techniques including wet layup, prepreg handling, and vacuum bagging. Students will also learn to perform essential bonded repairs on composite structures and evaluate repair integrity, as well as manage material storage, handling, and documentation requirements in compliance with industry standards.
This course prepares students to apply their knowledge and skills toward earning the following certifications:
- CertTEC Basic Composites Certification
- ACMA Certified Composite Technician (CCT)
- SAE-PRI General Composite Structural Bonded Repair Certification
Learning outcomes are structured to meet levels 1–3 of Bloom’s Taxonomy, ensuring students can remember, understand, and apply their skills effectively in aerospace and high-performance composite environments.
UPCOMING CLASSES
- October 13, 2025
- November 3, 2025
- December 1, 2025
Meet Your Instructor
Dr. Greg Mellema is a nationally recognized authority in advanced composites and aerospace technologies. With over 40 years of aviation experience, he combines the precision of a licensed A&P mechanic and the clarity of an accomplished educator. Additionally, as a certified FAA Part 107 Remote Pilot, Greg offers an exceptional blend of technical depth and instructional expertise.
Greg is currently serving as Educational Programs Manager at the Aerospace & Defense Training Center (ADTC) in Titusville, Florida, and plays a pivotal role in shaping the future aerospace workforce. His affiliations include the National Center for Autonomous Technologies (NCAT) and several national workforce development initiatives.
A prolific contributor to aerospace education, Greg has authored and co-authored multiple textbooks, training systems, and certification resources. His recent work includes the creation of a new textbook series aligned with the CertTEC, ACMA, and PRI composite technician certifications—helping students and professionals bridge the gap between classroom knowledge and industry performance.
His technical expertise centers on:
- Advanced composite manufacturing, including thermoset and thermoplastic systems, resin infusion processes, tooling, and adhesive bonding processes.
- Repair of advanced composite structures, with deep experience in bonded repair techniques, vacuum bagging, and inspection methodologies
- Training system design and certification preparation, aligning curriculum with industry standards to ensure technician readiness and workforce scalability
Greg’s background spans flightline and depot-level maintenance, aircraft inspection, UAV systems, and composite manufacturing—offering a truly comprehensive perspective on aerospace operations and innovation.
In his consulting work, Greg partners with colleges, OEMs, and government agencies to develop training systems, build technical programs, and expand workforce capabilities worldwide. His mission: to deliver hands-on, standards-aligned solutions that prepare the next generation of aerospace technicians for excellence.