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Key Responsibilities and Required Skills for Aluminum Fabrication Worker

💰 $40,000 - $65,000

ManufacturingFabricationSkilled TradesMetalworking

🎯 Role Definition

An Aluminum Fabrication Worker (Aluminum Fabricator) is responsible for producing, assembling, finishing, and inspecting aluminum components and structures to meet engineering drawings, blueprints, and quality standards. This role combines hands-on metalworking, precision measuring, welding/riveting, press brake and shear operation, and strict adherence to safety and material-handling protocols. The ideal candidate demonstrates proficiency with aluminum alloys, fabrication tools, and production processes in industries such as manufacturing, aerospace, marine, and construction.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Metal shop apprentice or Fabrication trainee
  • Production assembler or general laborer with shop experience
  • Sheet metal worker or structural fitter

Advancement To:

  • Lead Aluminum Fabricator / Shop Lead
  • Welding Technician / Certified Welder (MIG/TIG specialist)
  • CNC Operator / Programmer for metal cutting/forming machines
  • Manufacturing Supervisor / Production Manager

Lateral Moves:

  • Sheet Metal Fabricator
  • Structural/Boilermaker Fabricator
  • Quality Inspector / Dimensional Inspector

Core Responsibilities

Primary Functions

  • Read, interpret and execute work from blueprints, engineering drawings, CAD prints, and specification sheets to fabricate aluminum parts and assemblies that meet dimensional tolerances and finish requirements.
  • Set up and operate press brakes, hydraulic shears, roll formers, bending machines, and manual/automatic braking equipment to accurately form aluminum sheet and plate components per layout and bend schedules.
  • Operate and program CNC punching, plasma, laser, and waterjet cutting machines for aluminum parts; load/unload workpieces and verify machine output against part prints.
  • Perform MIG and TIG welding, brazing, and aluminum-specific welding techniques to join sheet, plate, and extruded sections while controlling heat input and preventing warping or distortion.
  • Lay out parts using jigs, templates, laser levels and precision measuring tools (calipers, micrometers, height gauges) and mark cutting, drilling and bending locations to tight tolerances.
  • Trim, deburr, grind and finish aluminum components using grinders, files, sanding machines, and polishing tools to remove burrs, sharp edges, and prepare surfaces for anodizing or painting.
  • Assemble, fit and install hardware, rivets, fasteners, inserts and subcomponents using pneumatic riveting tools, rivet guns, torque wrenches, and hand tools to meet assembly torque and fastening standards.
  • Inspect and verify part dimensions, hole locations, flatness and surface finish against inspection criteria; complete and maintain inspection documentation and non-conformance reports when required.
  • Perform dimensional checks and first-article inspections for new production runs; identify tooling or process adjustments to achieve print conformity and production repeatability.
  • Maintain, set up and adjust jigs, fixtures and templates for repeatable fabrication runs; fabricate simple fixtures and assist tooling engineers with prototype fixtures.
  • Operate band saws, cold saws, aluminum-specific cutoff wheels and bench tools safely to cut stock to length and minimize material waste.
  • Conduct pre-process material verification including alloy grade, temper, thickness and certifications; segregate material by job and document traceability when required by customer or regulatory standards.
  • Apply protective coatings, masking, and prepare surfaces for anodizing, painting or plating; advise finishing vendors on part geometry and handling to prevent damage.
  • Use lifting equipment (forklift, hoist, overhead crane) and proper rigging techniques to move heavy aluminum assemblies safely and position parts for assembly or machining.
  • Follow and enforce shop safety standards, PPE requirements, and OSHA/industry-specific safety regulations; participate in safety training and toolbox talks.
  • Troubleshoot fabrication issues on the floor — such as fit-up gaps, welding distortion, dimensional drift — and implement corrective actions to keep production on schedule.
  • Maintain accurate production records, traveler cards, routing sheets and time logs; communicate status updates to supervisors and planning for schedule adherence.
  • Collaborate with engineering and quality teams to suggest design or process improvements that reduce cost, improve manufacturability, or enhance part performance for aluminum components.
  • Support prototyping and R&D efforts by producing one-off parts and providing hands-on feedback on manufacturability, tolerances and assembly sequence.
  • Perform routine preventive maintenance on fabrication equipment (press brakes, welding machines, saws) and report or repair minor issues to minimize downtime.
  • Train and mentor junior fabricators, apprentices and temporary staff on aluminum-specific fabrication techniques, safe equipment operation and quality expectations.
  • Ensure proper housekeeping of work area, tool boards, and material storage to reduce damage to aluminum parts and maintain an efficient fabrication workflow.
  • Follow customer-specific procedures and documentation requirements (e.g., aerospace, marine specifications), including digital inspection records and certifications when required by contract.

Secondary Functions

  • Support continuous improvement initiatives, lean manufacturing projects, and 5S activities to increase shop efficiency and reduce scrap in aluminum fabrication.
  • Assist with job estimating by providing time, tooling and material input based on practical shop experience and historical production metrics.
  • Participate in cross-functional teams during new product introductions (NPI) to align fabrication processes with production schedules and quality goals.
  • Help coordinate inbound material handling and inventory checks for aluminum stock, extrusions and hardware; notify purchasing of low stock or obsolescence.
  • Contribute to process documentation updates, standard operating procedures (SOPs) and work instructions to reflect best practices and lessons learned.
  • Support ad-hoc prototype builds and urgent customer repairs, prioritizing tasks under guidance from the shop supervisor to meet delivery commitments.
  • Participate in internal audits, quality inspections, and supplier quality reviews as required to maintain industry certifications and customer approvals.
  • Attend periodic training on new tools, welding procedures, alloy handling, and safety compliance to maintain and expand fabrication skill sets.

Required Skills & Competencies

Hard Skills (Technical)

  • Blueprint reading and interpretation (geometric dimensioning & tolerancing GD&T) for fabrication prints
  • Press brake setup and operation, including bend deduction and k-factor calculation for aluminum
  • CNC operation and programming basics for laser, plasma, waterjet and punch machines
  • MIG and TIG welding on aluminum (GMAW/GTAW), aluminum wire/feed systems, and welding procedure adherence
  • Riveting and mechanical fastening (solid rivets, blind rivets, hi-loks, nutplates) and use of air riveting tools
  • Precision measuring with calipers, micrometers, height gauges, angle plates and protractors
  • Metal forming: shearing, rolling, bending, and stretch-form techniques specific to aluminum alloys
  • Cutting and sawing: band saw, cold saw, abrasive saws and CNC cutting technologies for aluminum stock
  • Use of hand and power tools: grinders, die grinders, drills, hammering tools and pneumatic tools
  • Part finishing and deburring techniques; surface prep for anodizing, painting or powder coating
  • Material identification and handling: aluminum alloys, tempers, and material certification traceability
  • Simple fixture and jig fabrication, layout skills and use of templates for repeatable production
  • Basic welding metallurgy for aluminum: heat control, distortion prevention and filler selection
  • Forklift and hoist operation for safe handling of large aluminum assemblies (if applicable/certified)

Soft Skills

  • Strong attention to detail and commitment to producing high-quality, dimensionally accurate work
  • Problem-solving mindset to troubleshoot fit-up, distortion and process variance on the floor
  • Clear verbal and written communication for working with supervisors, engineers and quality inspectors
  • Time management and ability to prioritize production tasks in a fast-paced environment
  • Team orientation and willingness to train or be trained; ability to collaborate across fabrication and finishing teams
  • Dependability, punctuality and a safety-first attitude in daily shop operations
  • Adaptability to work varying shifts, overtime and occasional urgent build requests
  • Continuous improvement mindset with openness to lean manufacturing practices and process standardization

Education & Experience

Educational Background

Minimum Education:

  • High school diploma or GED; vocational certificate in welding or metal fabrication preferred

Preferred Education:

  • Technical diploma or associate degree in Welding Technology, Fabrication, Manufacturing Technology, or related trade school certification

Relevant Fields of Study:

  • Welding Technology
  • Metal Fabrication / Manufacturing Technology
  • Industrial Maintenance / Machine Tool
  • Sheet Metal Fabrication

Experience Requirements

Typical Experience Range: 2–5 years of hands-on aluminum fabrication experience (entry-level applicants with strong trade school credentials or apprenticeship may be considered)

Preferred:

  • 3+ years fabricating aluminum components in a commercial, aerospace or marine environment
  • Demonstrated experience with press brake/CNC equipment, MIG/TIG welding on aluminum and quality inspection procedures
  • Certifications or training in welding (e.g., AWS), forklift operation, or industry-specific standards are a plus
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