Key Responsibilities and Required Skills for Jet Aircraft Machinist

🎯 Role Definition

A Jet Aircraft Machinist (Aerospace Machinist) is responsible for precision manufacturing, inspection, repair, and assembly of aircraft structural components and engine hardware to strict aerospace standards. The role requires mastery of CNC and manual machining, blueprint/GD&T interpretation, tolerance control, use of precision metrology tools, adherence to FAA/EASA regulations and quality standards (AS9100/ISO), and close collaboration with engineers, inspectors and production teams to ensure airworthiness and component reliability.

📈 Career Progression

Typical Career Path

Entry Point From:

Entry-level Machinist / Apprentice Machinist from general manufacturing or metalworking shops.
Aircraft Sheet Metal Technician or A&P mechanic transitioning into precision machine shop work.
CNC Operator or Setup Technician with experience in aerospace materials.

Advancement To:

Senior Aerospace Machinist / Lead Machinist overseeing shop workflow, quality and training.
Toolroom Supervisor or Machining Supervisor managing personnel, schedules and tooling budgets.
Manufacturing Engineer or CNC Programmer focused on process optimization and CAM programming.

Lateral Moves:

Quality Inspector / NDT Technician specializing in aerospace inspection methods.
Maintenance Technician for aircraft components or engine overhaul shops.

Core Responsibilities

Primary Functions

Read, interpret and apply complex engineering blueprints, prints and GD&T tolerancing to machine, fit and finish jet aircraft structural components and engine parts accurately and to aerospace specifications.
Program, set up, operate and optimize 3-axis to 5-axis CNC mills and CNC lathes for production and prototype jet engine parts, including fixture design, tool selection and G-code verification.
Perform precision manual machining (vertical/horizontal milling, turning, drill press work, and reaming) on exotic alloys such as titanium, Inconel, stainless steel, and aluminum for airframe and engine components while maintaining tight tolerances.
Use precision metrology equipment (CMM, micrometers, height gauges, bore gauges, dial indicators, surface plates) to inspect parts and verify dimensions, generate inspection reports, and act on out-of-tolerance conditions.
Fabricate, repair and modify aircraft fittings, brackets, bushings, shafts and housings, following engineering change orders (ECOs) and approved repair schemes to restore components to serviceable condition.
Perform hole drilling, countersinking, reaming and fastening prep to exact edge distances and pattern requirements, ensuring compliance with fatigue life, rivet specs and fastener clearance in structural components.
Execute secondary operations including deburring, finishing, chamfering, broaching and surface treatments to meet aerospace surface finish and corrosion prevention standards.
Follow and enforce FAA/EASA airworthiness directives, service bulletins, vendor specifications and company quality procedures during machining, repair and documentation activities.
Conduct first article inspections (FAI) and in-process inspections and provide detailed non-conformance reports (NCRs), corrective action recommendations and root-cause analysis when parts fail to meet specifications.
Maintain accurate traveler documentation, job routings, inspection records, tooling logs, material traceability and serial number records as required for airworthiness certification and AS9100/ISO compliance.
Develop and validate machining processes, cycle times and tooling lists for new parts or revisions in collaboration with manufacturing engineers and design teams to reduce cost and improve throughput.
Oversee setup and calibration of fixtures, vises and workholding devices and fabricate custom fixtures when necessary to ensure repeatability and stability during complex machining operations.
Participate in corrective and preventive maintenance of CNC machines, measurement tools and shop equipment, coordinate with maintenance teams to minimize downtime and ensure machining accuracy.
Utilize CAD/CAM software (SolidWorks, Mastercam, GibbsCAM, Siemens NX, CATIA) to generate toolpaths, simulate machining operations and refine programs for high-precision aerospace components.
Apply non-destructive inspection techniques (magnetic particle inspection, fluorescent dye penetrant, eddy current) or coordinate with NDT specialists to verify component integrity following machining or repair.
Manage tooling inventories, inspect cutting tools and inserts for wear, recommend tool breakage solutions and maintain cutting parameter control sheets to sustain consistent part quality.
Perform deburring and edge treatments consistent with fatigue life considerations and perform visual and tactile inspections to eliminate burrs, sharp edges and stress risers on critical components.
Interpret and apply material heat treatment and plating specification requirements (anodize, alodine, passivation, coatings) and coordinate with heat treat/plating vendors to ensure material properties meet final specifications.
Mentor and train junior machinists and apprentices on best practices for aerospace machining, blueprint reading, safe tool handling and inspection requirements to build shop capability.
Support production ramp-ups and prototype builds by providing rapid turn machining, fixture design and process documentation to meet program deadlines and minimize program risk.
Collaborate with engineering, quality and suppliers to troubleshoot manufacturing issues, recommend engineering changes for manufacturability, and implement cost-effective repairs while preserving part functionality.
Ensure strict adherence to shop safety programs, lockout/tagout procedures, hazardous material handling, and PPE usage while promoting a culture of continuous improvement and safety-first behavior.
Coordinate with procurement to verify material certifications (MTRs), manage stock rotation for aerospace alloys, and verify incoming raw material conformity before machining operations commence.
Apply shop mathematics and measurement science to perform tolerance stack-up analyses, calculate feeds and speeds, and optimize machining parameters to reduce cycle times and reject rates.
Prepare components for assembly including fit checks, trial assemblies, shimming, torqueing to specified values and ensuring mating parts align to engineering tolerances.

Secondary Functions

Assist in continuous improvement projects such as 5S, Kaizen events, and lean initiatives to reduce waste and improve shop flow and machining efficiency.
Support documentation updates for standard operating procedures (SOPs), work instructions and process control plans as machining processes evolve.
Help qualify and evaluate new cutting tools, coolants and machining technologies to increase tool life and part throughput.
Provide technical input during supplier audits and sub-tier machining procurements to confirm supplier capabilities align with aerospace quality requirements.
Participate in cross-functional program reviews, design for manufacturability (DFM) discussions and production readiness reviews to streamline product introduction.
Respond to urgent field repair requests or AOG (aircraft on ground) situations requiring rapid part fabrication or on-site repair support.
Support inventory cycle counts, tool crib operations and calibration scheduling to ensure measurement instruments are current and reliable.
Assist engineering with prototype adjustments and quick-turn modifications during development test cycles.

Required Skills & Competencies

Hard Skills (Technical)

Advanced blueprint reading and interpretation of complex engineering drawings, including geometric dimensioning and tolerancing (GD&T).
CNC programming and operation experience on mills and lathes (Mastercam, Siemens, Fanuc controls, Heidenhain), including multi-axis setups and toolpath optimization.
Proficiency in manual machining operations: vertical/horizontal milling, precision turning, drilling, reaming, broaching and tapping on aerospace materials.
Precision inspection and metrology skills: CMM programming/operation, micrometers, calipers, height gauges, bore gauges, dial indicators and surface plate use.
Experience machining aerospace alloys: titanium, Inconel, stainless steels, aluminum alloys and working knowledge of their machining characteristics.
Familiarity with CAD/CAM tools (SolidWorks, CATIA, NX) for part review, fixture design and generating CNC programs.
Knowledge of non-destructive testing methods (MT, PT, eddy current) and ability to coordinate NDT inspections with certified technicians.
Strong understanding of FAA/EASA airworthiness requirements, AS9100 quality standards, material traceability and certification processes.
Shop math and tolerance analysis skills for calculating feeds, speeds, cutting forces and tolerance stack-ups.
Experience with tooling selection, workholding/fixture design, cutting tool coatings and coolants tailored for high-performance alloys.
Ability to create and maintain detailed manufacturing documentation: travelers, routings, FAI reports, NCRs and maintenance logs.
Familiarity with ERP/MRP systems (e.g., SAP, Epicor, NetSuite) for production orders, part tracking and inventory management.
Experience with surface treatments and finishing processes (anodizing, passivation, plating) and coordinating vendor treatments.

Soft Skills

Strong attention to detail and commitment to part quality and airworthiness.
Effective verbal and written communication for reporting inspection results, deviations and process changes.
Problem-solving mindset with ability to troubleshoot machining and fitment issues under time constraints.
Team-oriented approach and ability to collaborate with engineers, quality inspectors and production planners.
Time management and prioritization skills to meet demanding production schedules and urgent repairs.
Adaptability to new tooling, technology and process improvements.
Commitment to workplace safety, regulatory compliance and maintaining a clean and organized shop environment.
Mentorship and coaching ability to train junior machinists and apprentices.

Education & Experience

Educational Background

Minimum Education:

High school diploma or GED with vocational training in machining, tool and die, or equivalent military training (Aerospace/Armament machinist specialties).

Preferred Education:

Associate degree or certificate in Precision Machining, Tool & Die, Manufacturing Technology, or Aerospace Manufacturing.
Additional certifications: FAA 145 shop experience, AS9100, IPC, or relevant machining certifications (NIMS, AMT).

Relevant Fields of Study:

Precision Machining / CNC Technology
Aerospace Manufacturing / Aviation Maintenance
Manufacturing Engineering / Tool & Die

Experience Requirements

Typical Experience Range: 3–10+ years of hands-on aerospace/jet aircraft machining experience, including both CNC and manual machining of aircraft components.

Preferred:

5+ years machining experience in aerospace or defense programs with documented work on jet engine hardware or structural aircraft components.
Demonstrated experience with GD&T, FAI processes, CMM inspection and AS9100-compliant documentation.
Previous experience working in FAA-regulated environments or military aviation maintenance is highly desirable.