Advanced Composite Materials - Level 1
COURSE DESCRIPTION
This intensive 5-day course provides foundational knowledge and hands-on training in composite materials, fabrication, and structural repair. Designed for technicians, engineers, and inspectors, it introduces participants to the terminology, materials, and processes used in advanced composites. Students will gain real-world experience working with carbon fiber, fiberglass, and aramid reinforcements, honeycomb and foam cores, and epoxy resin systems. The course integrates traditional wet layup and prepreg techniques with contemporary bonding, vacuum bagging, and composite repair processes to build practical skills aligned with industry standards.
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.
LEARNING OBJECTIVES
1.1 Describe the key applications and
performance characteristics of advanced composite materials. (1)
1.2 Identify general classes of composite structures including laminate and sandwich panels. (1)
2.1 List and distinguish common fiber types: carbon, glass, and aramid. (1)
2.2 Interpret fabric styles, weave patterns, and describe ply orientation concepts such as the warp
clock. (2)
3.1 Describe thermoset and thermoplastic resin systems used in aerospace composites and their cure
requirements. (1)
3.2 Explain proper adhesive selection, storage, out-time, and surface prep techniques. (2)
4.1 Demonstrate proper hand layup technique using prepreg and wet layup materials. (3)
4.2 Apply vacuum bagging materials in
correct sequence and test for system integrity. (3)
4.3 Identify common tooling materials. (1)
5.1 Perform damage removal, core fill, and wet layup patch repair per supplied procedure. (3)
5.2 Describe proper hole drilling and fastener selection for composites. (3)
5.3 Describe proper surface prep methods for adhesive bonding of metals and composites. (1)
6.1 Evaluate laminate quality by performing visual and tap-test inspections and calculating
resin-to-fiber ratios on test specimens. (3)
6.2 Follow safety procedures for PPE, SDS usage, and safe handling of composites. (2)
6.3 Identify destructive and non-destructive
inspection methods (1)
UPCOMING CLASSES
- September 21, 2025, Pay for this date using the below button.
- October 6, 2025, Pay for this date using the below button.
- November 3, 2025, Pay for this date using the below button.
- December 1, 2025, Pay for this date using the below button.
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.