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Key Responsibilities and Required Skills for Aluminum Structural Technician

💰 $45,000 - $85,000

ManufacturingAerospaceFabricationStructural AssemblyQuality Control

🎯 Role Definition

An Aluminum Structural Technician is a hands-on manufacturing professional responsible for building, repairing and inspecting aluminum structural components and assemblies to strict engineering specifications. Working primarily in aerospace, defense, marine or industrial fabrication environments, the technician interprets engineering drawings and work instructions, performs precision drilling, countersinking, riveting, fastening and bonding operations, and documents quality data to ensure airworthiness and structural integrity. This role requires strong blueprint literacy, proficiency with hand and pneumatic tools, and a commitment to safety and process compliance.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Sheet Metal Apprentice or Journeyman
  • Aircraft Assembly Technician
  • Fabrication or Mechanical Assembler

Advancement To:

  • Senior Aluminum Structural Technician / Lead Assembler
  • Structural Repair Specialist or Structural Inspector (NDT)
  • Manufacturing Supervisor or Production Lead

Lateral Moves:

  • Composites Technician
  • Nondestructive Testing (NDT) Technician
  • Quality Assurance / Quality Control Technician

Core Responsibilities

Primary Functions

  1. Interpret engineering drawings, blueprints, specifications and assembly procedures to lay out and build aluminum structural assemblies to exact tolerances and engineering requirements.
  2. Perform precision drilling, countersinking, reaming and deburring of aluminum skins, frames, ribs and fittings using drill presses, hand drills and portable equipment while maintaining hole size and positional accuracy.
  3. Install and set solid and blind rivets (e.g., AN, Hi-Lok, CherryMAX), flush and protruding fasteners, and torque-installed mechanical fasteners according to published torque charts and assembly instructions.
  4. Utilize pneumatic riveting tools, bucking bars, rivet squeezers and vacuum-set tooling to achieve required fastener flushness, grip and shear values for structural integrity.
  5. Prepare mating surfaces for adhesive bonding, including cleaning, priming and applying structural adhesives in strict accordance with work instructions and safety data sheets.
  6. Perform aluminum sheet metal shaping, trimming, forming and fitting operations to achieve proper panel fit and edge conditions prior to final assembly.
  7. Carry out non-destructive inspection tasks (visual inspection, dye penetrant, eddy current or ultrasonic as applicable) to identify cracks, delamination, corrosion or other structural anomalies.
  8. Execute repair procedures for damaged aluminum structures including removal of damaged sections, forming replacement parts, and reinstalling using rivets, bolts or adhesive bonding.
  9. Operate basic machining and secondary equipment (presses, deburring tools, countersink machines) and request or adjust tooling and fixtures as required for assemblies.
  10. Read and interpret GD&T (geometric dimensioning and tolerancing) and apply measurement techniques with calipers, micrometers, depth gauges and protractors to validate part dimensions.
  11. Maintain part traceability and documentation by completing travelers, inspection records, C of C paperwork and electronic manufacturing records in adherence with AS9100/ISO quality systems.
  12. Follow company and regulatory safety, chemical handling and hazardous material procedures, including use of PPE, ventilation, and proper disposal of solvents and primers.
  13. Participate in first article inspections and support production audits by providing measured data, photos and corrective action input to engineering and quality teams.
  14. Set up and adjust jigs, fixtures and temporary fasteners to ensure assemblies are straight, square and meet stress/deflection requirements prior to final fastening.
  15. Collaborate with engineering and production planners to identify out-of-tolerance parts, suggest rework methods, and implement corrective actions to minimize scrap and rework cost.
  16. Train and mentor junior technicians and apprentices on fabrication techniques, safe tool operation and quality expectations for aluminum structural work.
  17. Support continuous improvement initiatives by logging process observations, participating in root cause analyses, and trialing improvements to reduce cycle time and defect rates.
  18. Ensure inventory of structural consumables (rivets, sealants, primers, fasteners) is maintained and submit requests for tooling refurbishment or replacement when needed.
  19. Work shifts and production schedules as required, including lean/kaizen events, and maintain strong communication with supervisors and downstream assembly teams.
  20. Adhere to export control, ITAR and company confidentiality policies when handling drawings, tooling and supplier data for controlled aerospace hardware.
  21. Coordinate with NDT and quality teams to approve repairs and conformance prior to releasing structure for functional testing or flight/field use.
  22. Perform post-installation checks (gap, flush, torque re-checks) and surface prep for corrosion prevention treatments (alodine, primer) per engineering instruction.
  23. Maintain a clean, organized work area and ensure tooling calibration records are up-to-date to meet internal audit requirements.

Secondary Functions

  • Support production planning by providing feedback on assembly cycle times and tooling needs.
  • Assist in updating work instructions, standardized work documents and visual aids for assembly operations.
  • Contribute material condition reports and help prioritize repairs for incoming parts.
  • Participate in cross-functional meetings with quality, engineering and supply chain to resolve technical issues.
  • Help coordinate off-line fabrication tasks and subcontractor work when assemblies require specialty operations.

Required Skills & Competencies

Hard Skills (Technical)

  • Blueprint Reading & Interpretation — proficient at reading engineering drawings, BOMs and GD&T.
  • Riveting & Fastening — experienced with solid rivets, blind rivets (CherryMAX/Hi-Lok) and torque-controlled bolting.
  • Precision Drilling & Countersinking — accurate hole preparation and edge treatment to aerospace tolerances.
  • Measurement & Inspection — skilled using calipers, micrometers, dial indicators and height gauges.
  • Surface Preparation & Bonding — experience with adhesive application, surface cleaning, priming and alodine processes.
  • Hand & Pneumatic Tools — expert use of rivet guns, countersink cutters, pneumatic drills and bucking bars.
  • NDT Familiarity — working knowledge of visual inspection and basic dye-penetrant or eddy current practices (as applicable).
  • Structural Repair Techniques — ability to remove and replace damaged skins, stringers and fittings with approved methods.
  • Quality Systems & Documentation — familiar with AS9100/ISO practices, part traceability and completing inspection paperwork.
  • Tooling & Fixture Setup — ability to set and maintain jigs, fixtures and temporary fasteners for assembly.
  • Safety & Hazardous Materials — knowledge of PPE, MSDS/SDS for adhesives, solvents and primers.
  • Basic Computer Skills — competence with electronic manufacturing records, maintenance of digital travelers and SAP/MRP entry (preferred).

Soft Skills

  • Attention to Detail — high level of accuracy for measurement, torque and fastener installation.
  • Problem Solving — practical approach to diagnosing fit, tolerance and finish issues on assemblies.
  • Communication — clear verbal and written skills to relay inspection results and process deviations.
  • Teamwork — collaborates effectively with engineers, inspectors and production planners.
  • Time Management — able to prioritize tasks to meet production schedules and deadlines.
  • Continuous Improvement Mindset — proactive in suggesting process improvements to enhance quality and throughput.
  • Dependability — reliable attendance, adherence to schedules and strong work ethic.
  • Adaptability — comfortable working in changing production environments and adopting new techniques.
  • Coaching & Mentoring — ability to guide junior staff and support skill development.
  • Safety Focus — consistently models safe work practices and supports a safety-first culture.

Education & Experience

Educational Background

Minimum Education:

  • High school diploma or GED with vocational training in sheet metal, manufacturing or a related trade.

Preferred Education:

  • Associate degree or technical certificate in Aerospace Manufacturing Technology, Sheet Metal Fabrication, Welding or Mechanical Technology.
  • Trade school certification in aircraft structural assembly or rivet-setting.

Relevant Fields of Study:

  • Aerospace Manufacturing
  • Sheet Metal Technology
  • Welding & Fabrication
  • Mechanical Engineering Technology
  • Industrial Maintenance

Experience Requirements

Typical Experience Range: 2–7 years of hands-on aluminum structural assembly or aircraft structural work.

Preferred:

  • 3–5+ years in aerospace or defense structural assembly with demonstrated competency in riveting, drilling, countersinking and inspection.
  • Certifications such as FAA AC 43 basic knowledge, NCCER, AWS (TIG/Aluminum) or company-specific qualifications are advantageous.
  • Experience working under AS9100 quality systems, ITAR-controlled environments and with NADCAP processes is a plus.
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