This unit applies to the manufacture of investment casting dies and polymer patterns for medium production castings, core boxes, tooling aids, jigs and checking fixtures etc.

Construction includes, but is not limited to, solid polymer, filled, laminated fibreglass or metal inserts.

Band: A

Unit Weight: 8

Path 1

MEM07005C

Perform general machining

MEM09002B

Interpret technical drawing

MEM12023A

Perform engineering measurements

MEM13003B

Work safely with industrial chemicals and materials

MEM18001C

Use hand tools

ELEMENT

PERFORMANCE CRITERIA

1. Inspect and prepare patterns and cores

1.1. Patterns or cores are inspected for appropriate surface finish and set up on jointline or flat board to specification.

1.2. Appropriate parting agent is selected and applied to polymer specifications.

2. Manufacture moulds, patterns, tooling aids etc.

2.1. Appropriate polymer materials are selected to specification.

2.2. Polymer and hardener are mixed to correct ratios and specifications using standard safety and operating procedures.

2.3. Polymer is applied to specification and using predetermined methods, ensuring that air is not entrapped in application, excessive heat is not generated and delamination does not occur in final use.

2.4. Pattern/core box is stripped, inspected, cleaned and repaired as required.

2.5. Faces of polymer pattern are machined and finished to specifications.

2.6. Appropriate method of location is applied to patterns and core boxes.

2.7. Polymer tooling is checked for conformance to specifications as required.

Required skills

Look for evidence that confirms skills in:

reading, interpreting and following information on written job instructions, specifications, standard operating procedures, charts, lists, drawings and other applicable reference documents

undertaking numerical operations, geometry and calculations/formulae within the scope of this unit, including determination of contraction rates

measuring polymer materials

interpreting written instructions, sketches and drawings

making master patterns

machining patterns/core boxes and tooling aids

sealing the patterns or cores with appropriate surface finish

alignment of pattern to core box

setting up with necessary locations

applying the parting agents

selecting polymers

preparing polymer and hardener

applying polymer coating

releasing patterns and moulds

cleaning patterns and moulds

Required knowledge

Look for evidence that confirms knowledge of:

machining for pattern making

parting agents

safe working procedures

methods of locating patterns and core boxes

the range of surface finishes

range of polymers and their applications

mixing ratios and calculations

characteristics of polymer under exothermic reaction

exothermic control procedures

methods of stripping

pattern checking techniques

use and application of personal protective equipment

safe work practices and procedures

hazards and control measures associated with producing polymer patterns

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

A person who demonstrates competency in this unit must be able to produce polymer patterns. Competency in this unit cannot be claimed until all prerequisites have been satisfied.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Assessors must be satisfied that the candidate can competently and consistently perform all elements of the unit as specified by the criteria, including required knowledge, and be capable of applying the competency in new and different situations and contexts.

Context of and specific resources for assessment

Assessors should gather a range of evidence that is valid, sufficient, current and authentic. Evidence can be gathered through a variety of ways including direct observation, supervisor's reports, project work, samples and questioning. Questioning techniques should not require language, literacy and numeracy skills beyond those required in this unit of competency. The candidate must have access to all tools, equipment, materials and documentation required. The candidate must be permitted to refer to any relevant workplace procedures, product and manufacturing specifications, codes, standards, manuals and reference materials.

This unit could be assessed in conjunction with any other units addressing the safety, quality, communication, materials handling, recording and reporting associated with producing polymer patterns or other units requiring the exercise of the skills and knowledge covered by this unit.

Method of assessment

Assessors should gather a range of evidence that is valid, sufficient, current and authentic. Evidence can be gathered through a variety of ways including direct observation, supervisor's reports, project work, samples and questioning. Questioning techniques should not require language, literacy and numeracy skills beyond those required in this unit of competency. The candidate must have access to all tools, equipment, materials and documentation required. The candidate must be permitted to refer to any relevant workplace procedures, product and manufacturing specifications, codes, standards, manuals and reference materials.

Guidance information for assessment

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Surface finish

Texture, gel coat, aluminium fill

Parting agent

Wax, PVA

Polymer materials

Epoxy resins, urethane

Method of location

Male and female joint, pin and bush

Unit sector

Casting and moulding

This unit contains employability skills.