Explore how composite materials are made, their properties, and real-world applications. Complete hands-on projects to earn this merit badge.

Requirements

  1. 1. Safety & Responsibility

    Do the following:

    Do all
    1. a.

      Safety Hazards & Protective Gear

      Explain to your counselor the most likely hazards you may encounter while working with composite materials and what you should do to anticipate, mitigate, and prevent, and respond to these hazards. Describe the appropriate safety gear and clothing that should be used when working with composite materials.
    2. b.

      Handling, Storage & Disposal

      Explain the precautions that must be taken when handling, storing, and disposing of resins, reinforcements, and other materials used in composites. Include in your discussion the importance of health, safety, and environmental responsibility and awareness.
    3. c.

      Safety Data Sheets

      Describe what a safety data sheet (SDS) is and tell why it is used.

  2. 2. Understanding Composites

    Do the following:

    Do all
    1. a.

      What Are Composites?

      Explain what composite materials are. Include a brief history of composites and how they have developed.
    2. b.

      Composites vs. Traditional Materials

      Compare the similarities and differences between composites and wood, aluminum, copper, and steel. Describe the physical, electrical, mechanical, corrosive, flammability, cost, and other such properties. For each of these raw materials, give one example of how it can be shaped and used for a specific application.

  3. 3. How Composites Are Made

    Do all
    Describe how composite materials are made. Then do the following:
    1. a.

      Reinforcement Materials

      Discuss three different composite reinforcement materials, their positive and negative characteristics, and their uses. Obtain the SDS for each one and discuss the toxicity, disposal, and safe-handling sections for these materials.
    2. b.

      Resins

      Discuss three different resins used in composites, their positive and negative characteristics, and their uses. Obtain the SDS for each one and discuss the toxicity, disposal, and safe-handling sections for these materials. Include thermoset resins and thermoplastic resins in your discussion.
    3. c.

      New Resin Applications

      For each of the three resins you chose for requirement 3(b), think of a new application that might be worth developing.

  4. 4. Real-World Composites

    Explore the Industry

    Choose 1
    With your parent or guardian’s permission and your counselor’s approval, do ONE of the following:
    1. Visit a company that manufactures or repairs products made with composites. Discuss what you learned with your counselor.
    2. Find three composites-related websites. Share and discuss what you learned with your counselor.

  5. 5. Building with Composites

    Do the following:

    Do all
    1. a.

      Hands-On Projects

      Use composite materials to complete two projects, at least one of which must come from the Composite Materials merit badge pamphlet. The second project may come from the pamphlet OR may be one you select on your own that has been approved by your counselor in advance.
    2. b.

      Finding a Workspace

      With your counselor’s assistance, find an appropriate site where the projects can be safely completed under your counselor’s supervision and/or the supervision of an adult approved by your counselor who is knowledgeable about composites.
    3. c.

      Evaluating Your Work

      With your counselor, determine how the finished projects will be evaluated. Using those guidelines, evaluate the completed projects with your counselor.

  6. 6. Your Composites Future

    Careers & Hobbies

    Choose 1
    Do ONE of the following:
    1. Explore careers related to the Composite Materials merit badge. Research one career to learn about the training and education needed, costs, job prospects, salary, job duties, and career advancement. Your research methods may include—with your parent or guardian’s permission—an internet or library search, an interview with a professional in the field, or a visit to a location where people in this career work. Discuss with your counselor both your findings and what about this profession might make it an interesting career.
    2. Explore how you could use knowledge and skills from the Composite Materials merit badge to pursue a hobby or interest. Research any training needed, expenses, and organizations that promote or support it. Discuss with your counselor what short-term and long-term goals you might have if you pursued this.