Composite Automated Tape Layers (ATL) Operator & Technician Training

Offered by Pertecnica Engineering

Automated Tape Layer (ATL) machines are advanced composite manufacturing systems used to lay continuous carbon or glass fiber tapes onto molds or mandrels with high precision. This process enables the production of large, lightweight, and high-strength composite parts for aerospace, automotive, and wind energy applications. ATL technology ensures consistent fiber orientation, minimal defects, and optimized structural performance in complex geometries.

In modern industries, ATL is essential for producing large composite panels, fuselage sections, and wind turbine blades. Skilled operators and technicians are required to manage machine setup, tape tension, path programming, and quality control. This training program emphasizes practical, hands-on learning to develop industry-ready skills in automated composite tape laying.

Top 6 Industries Using This Technology

1. Aerospace Manufacturing
Used for laying composite fuselage sections, wings, and structural components.

2. Wind Energy
Applies in manufacturing large turbine blades and aerodynamic structures.

3. Automotive Industry
Used for lightweight body panels, structural components, and performance parts.

4. Marine Industry
Applies in producing composite hulls, decks, and marine structures.

5. Defence Manufacturing
Used for lightweight, high-strength armor and structural components.

6. Sports & Leisure Equipment
Applies in producing high-performance bicycles, skis, and other composite sports gear.

Operator Training Coverage

  • Understanding ATL machine configuration and workflow
  • Identification of key components: tape head, mandrel/mold, tensioning system, and CNC controller
  • Tape handling, storage, and preparation
  • Machine setup, alignment, and programming for tape paths
  • Monitoring tape tension, placement accuracy, and layer consistency
  • Inspection for defects, voids, and overlaps
  • Safety practices in composite manufacturing environments
  • Basic preventive maintenance support

Operational Challenges & Handling

  • Tape Misalignment or Wrinkles
    Managed by proper tension control, machine calibration, and path programming
  • Air Bubbles or Voids
    Controlled through correct tape laying speed, pressure, and environmental conditions
  • Complex Geometry Handling
    Addressed using advanced CNC programming and mandrel setup
  • Tool Wear or Tape Head Issues
    Reduced through regular inspection and maintenance
  • Machine Downtime
    Minimized through preventive maintenance and monitoring

Who Can Join This Training

  • Operators and technicians working in composite manufacturing
  • Production personnel in aerospace, automotive, wind energy, and marine industries
  • Maintenance staff responsible for automated tape laying machines
  • Professionals seeking skill enhancement in advanced composite manufacturing
  • Individuals involved in lightweighting and structural composites

Training Outcomes

  • Ability to operate ATL machines efficiently and safely
  • Practical understanding of automated composite tape laying processes
  • Skills to produce high-strength, defect-free composite structures
  • Enhanced employability in aerospace, automotive, wind energy, and marine sectors
  • Industry-ready competencies for operator and technician roles

5-Day Course Curriculum

Day 1: Introduction & Industrial Applications

  • Overview of ATL technology and benefits
  • Applications across key industries
  • Advantages over manual composite layup
  • Safety practices in composite manufacturing

Day 2: Machine Components & System Understanding

  • Tape head, mandrel/mold, and tensioning system
  • CNC controller and interface basics
  • Material handling and tape storage
  • Environmental considerations and quality control

Day 3: Machine Operation & Process Control

  • Machine setup and calibration
  • Tape path programming and layer sequencing
  • Tension and pressure management
  • Monitoring placement accuracy and layer quality

Day 4: Practical Training & Hands-On Operation

  • Live ATL machine demonstration
  • Tape laying practice on sample components
  • Inspection of alignment, layer consistency, and defect detection
  • Real-time operator training

Day 5: Maintenance & Troubleshooting

  • Preventive maintenance practices
  • Common tape laying issues and solutions
  • Tape head and machine inspection
  • Ensuring consistent part quality and machine efficiency

Why Pertecnica Engineering

  • Industry-focused training aligned with advanced composite manufacturing
  • Strong emphasis on hands-on practical learning
  • Designed and delivered by experienced professionals
  • Focus on operator and technician-level competencies
  • Enhances precision, quality, and structural performance skills
  • Trusted training provider for aerospace, automotive, wind energy, and marine workforce development

This training program equips participants with practical expertise in Automated Tape Layer (ATL) operations, enabling them to produce lightweight, high-strength composite components efficiently, maintain consistent quality, and meet the demanding standards of modern aerospace, automotive, and wind energy industries