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Key Responsibilities and Required Skills for Aluminum Fabricator

💰 $ - $

🎯 Role Definition

The Aluminum Fabricator is responsible for producing, assembling and finishing aluminum parts and subassemblies to engineering drawings and quality standards. This role combines hands-on metalworking (cutting, bending, forming, welding, riveting, fastening), inspection to tight tolerances, fixture setup, and collaboration with engineering to support production, prototyping and continuous improvement initiatives. Ideal candidates demonstrate proven experience with aluminum alloys, TIG/MIG welding on aluminum, sheet metal forming, and a safety-first mindset.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Fabrication Apprentice / Trade School Graduate
  • Sheet Metal Worker or General Metal Fabricator
  • Welder (TIG/MIG) with aluminum experience

Advancement To:

  • Senior/Lead Aluminum Fabricator
  • Fabrication Supervisor or Team Lead
  • Manufacturing Engineer or Process Engineer
  • Quality Inspector / Welding Inspector (CWI/AWS certifications)

Lateral Moves:

  • CNC Operator / Programmer (tube/turret brake/cutting machines)
  • Prototyping / R&D Technician
  • Maintenance Technician (mechanical/pneumatic systems)

Core Responsibilities

Primary Functions

  • Read, interpret and apply engineering drawings, blueprints, CAD prints and specifications to fabricate aluminum parts and assemblies to dimensional tolerances and finish requirements.
  • Cut, shear and trim aluminum sheet, plate and extrusion stock using saws, shears, plasma cutters and CNC cutting equipment while optimizing material yield and minimizing scrap.
  • Set up and operate press brakes, rollers, cornices and forming machines to bend and form aluminum components to specified radii and angles, ensuring dimensional accuracy and consistent part geometry.
  • Perform TIG and MIG welding on aluminum alloys (including 6061, 5052, 5083, etc.), selecting appropriate filler metals, shielding gas, and welding parameters for strength and corrosion resistance.
  • Fit, clamp and assemble complex subassemblies using jigs, fixtures, riveters (solid and blind rivets), fasteners, adhesives and mechanical joining methods to meet engineering and assembly standards.
  • Bench fit and tack-weld prototypes, production pieces and one-off custom components, verifying alignment and fit before final welding and finishing.
  • Operate and program CNC machinery (plasma, laser, turret punch, punching, router) for precision cuts and hole patterns; verify setup and execute part runs to print.
  • Perform precise measuring and inspection using calipers, micrometers, height gauges, CMMs, templates and go/no-go gauges to verify conformance to DOCs and GD&T where applicable.
  • Deburr, sand, grind and finish welded and formed edges to specified surface finish standards and preparation levels for anodizing, painting or powder coat.
  • Prepare parts for surface treatments — clean, mask, apply solvents and ensure compliance with anodizing/painting vendor requirements and part cleanliness protocols.
  • Assemble final products, install hardware, seals, gaskets and fasteners to torque specifications and according to assembly instructions and quality checklists.
  • Maintain accurate production documentation and traveler records, including material lot numbers, weld logs, inspection records and first article inspection (FAI) reports.
  • Troubleshoot fabrication issues by diagnosing fit, weld defects, distortion and tooling problems; propose corrective actions and document root cause.
  • Set up and maintain fixtures, templates and tooling; modify or create simple jigs and fixtures to increase efficiency and repeatability of complex assemblies.
  • Execute prototype builds and small run production with iterative feedback to engineering, supporting design-for-manufacture improvements and rapid iteration cycles.
  • Adhere to all safety protocols including PPE usage, hot work permits, hazard communication and confined space/lockout-tagout procedures where applicable to maintain a safe shop environment.
  • Follow lean manufacturing and 5S practices to maintain organized workstations, reduce waste and continuously improve throughput and quality.
  • Participate in quality assurance processes, including first article inspections, in-process checks and final inspections; escalate nonconforming parts and document NCRs.
  • Train and mentor junior fabricators and apprentices on aluminum-specific techniques, safe welding practices, and blueprint reading.
  • Perform routine preventive maintenance and basic repairs on fabricating equipment, welding machines and hand tools to ensure uptime and reliability.
  • Handle, store and track aluminum raw materials and subcomponents; perform inventory cycle counts and coordinate material requests with purchasing.
  • Collaborate with engineers, planners and quality teams to review engineering changes, update work instructions and implement process control improvements that reduce rework and cost.
  • Work to production schedules while balancing quality, lead-time and scrap reduction goals; communicate progress and constraints to supervisors and planners.
  • Ensure compliance with industry standards (AWS, ISO, AS9100 where applicable) and company procedures for traceability, documentation and product safety.

Secondary Functions

  • Support continuous improvement events (Kaizen) and apply lean tools to reduce cycle time and improve shop flow.
  • Assist in creating standard work instructions, process sheets and inspection checklists for new parts and processes.
  • Participate in cross-functional problem-solving with maintenance, purchasing and quality to resolve supply or tool-related production bottlenecks.
  • Help evaluate new tooling, fixtures and welding consumables for cost, quality and manufacturability benefits.
  • Provide hands-on support during product launches and ramp-up phases, including extra shifts or flexible scheduling as needed.
  • Maintain a clean and organized work area, dispose of scrap metals properly and help enforce shop housekeeping standards.
  • Contribute to safety and training committees by providing feedback on hazards and improvement opportunities.
  • Support vendor and customer audits by preparing required documentation and demonstrating fabrication processes when requested.
  • Assist with small equipment calibration checks and routine measuring device verification.
  • Take part in continuous skills development, cross-training in adjacent fabrication technologies (CNC, finishing, assembly).

Required Skills & Competencies

Hard Skills (Technical)

  • Proficient blueprint and technical drawing reading, including GD&T interpretation and tolerance stack-up awareness.
  • TIG welding aluminum (AC) and MIG welding aluminum (GMAW-Al) with experience selecting filler rods/wires and shielding gases.
  • Experience with fabrication equipment: press brakes, rollers, shear, band saws, TIG/MIG welders, rivet guns, pneumatic rivet tools and CNC cutting machinery.
  • Sheet metal forming and bending expertise for thin-to-medium gauge aluminum.
  • Strong measurement and inspection skills using calipers, micrometers, height gauges, dial indicators and familiarity with CMM reports.
  • Knowledge of aluminum metallurgy and common alloys (e.g., 6061, 5052) and how heat input affects distortion and mechanical properties.
  • Proficiency in basic CNC operation and job setup (plasma/laser/turret) or the ability to quickly learn CNC interfaces.
  • Experience with fastening systems: solid blind rivets, structural rivets, Hi-Lok/Hi-Shear, lockbolts, adhesives and mechanical fasteners.
  • Familiarity with surface preparation techniques for anodizing, painting and powder coat, including solvent cleaning and masking.
  • Competence with fabrication documentation: traveler completion, weld logs, first article inspection (FAI) and nonconformance reporting (NCR).

Soft Skills

  • Strong attention to detail and commitment to producing parts within specified tolerances and finish requirements.
  • Problem-solving mindset and ability to troubleshoot root causes of fit, weld or tooling issues.
  • Good communication skills to collaborate with engineers, quality and manufacturing planners and to document findings clearly.
  • Time management and organization to prioritize multiple work orders and hit production schedules.
  • Team player attitude with willingness to mentor junior staff and cross-train across related areas.
  • Adaptability to changing priorities during prototyping and production ramp-ups.
  • Safety-oriented approach and ability to follow and enforce safety procedures.
  • Initiative for continuous improvement and openness to feedback and process changes.

Education & Experience

Educational Background

Minimum Education:

  • High school diploma or GED with vocational/trade school training in welding or metal fabrication preferred.

Preferred Education:

  • Technical certificate or associate degree in Welding Technology, Fabrication, Sheet Metal Technology or Mechanical Technology.
  • Certifications such as AWS D1.2 (or relevant aluminum welding certification), CWI (Certified Welding Inspector), NCCER or OSHA safety training are a plus.

Relevant Fields of Study:

  • Welding Technology / Welding Engineering Technology
  • Mechanical / Manufacturing Technology
  • Sheet Metal Fabrication / Metalworking

Experience Requirements

Typical Experience Range:

  • 2 to 7+ years fabricating aluminum components in a production, aerospace, marine, automotive or industrial manufacturing environment.

Preferred:

  • 3–5+ years of direct aluminum fabrication experience including TIG welding and sheet metal forming, or equivalent combination of education and hands-on experience.
  • Experience working to AS9100, ISO or other regulated quality systems a strong plus.
  • Prior exposure to CAD/CAM files, prototype builds, and collaborative work with engineering on manufacturability improvements.
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