Key Responsibilities and Required Skills for Jet Aircraft Sheet Metal Worker

🎯 Role Definition

The Jet Aircraft Sheet Metal Worker (also known as Aircraft Structural Technician or Sheet Metal Technician) is responsible for inspecting, fabricating, repairing, and installing structural components on jet aircraft in accordance with OEM manuals, structural repair manuals (SRMs), and FAA/regulated maintenance standards. This role demands precision metalworking skills, knowledge of rivet and fastener systems, corrosion control, blueprint interpretation, and strict adherence to safety and airworthiness requirements. Ideal for technicians with aviation sheet metal experience on large transport, regional, or business jets.

📈 Career Progression

Typical Career Path

Entry Point From:

Sheet metal apprentice or trade school graduate (Aerospace Sheet Metal)
A&P (Airframe & Powerplant) mechanic transitioning into structural work
Aircraft assembler or production sheet metal technician

Advancement To:

Senior Jet Aircraft Sheet Metal Worker / Lead Structural Technician
Structural Repair Supervisor or Shop Foreman
Aircraft Maintenance Supervisor, Quality Inspector, or Structural Design Technician

Lateral Moves:

NDT (Non-Destructive Testing) Technician
Composite Repair Technician
Airframe Maintenance Technician (Line or Heavy Maintenance)

Core Responsibilities

Primary Functions

Inspect aircraft airframe and structural components (skins, stringers, ribs, bulkheads, longerons) to identify damage, corrosion, cracks, and deformation; document findings and recommend repairs per SRM/OEM instructions.
Read, interpret and apply engineering drawings, blueprints, structural repair manuals (SRMs), wiring diagrams, and OEM service bulletins to plan and perform sheet metal repairs and modifications.
Fabricate and form sheet metal parts using hand tools, power tools, press brakes, rollers, shears, notchers, and CNC forming equipment to exact OEM tolerances for jet aircraft applications.
Remove damaged panels, structure, and fasteners safely using approved procedures; prepare mating surfaces, deburr, countersink, and dimple as required prior to installation.
Lay out, cut, fit, and install skins, doublers, splice plates, and reinforcement members using accurate measurement techniques to maintain aerodynamic and structural integrity.
Install and set rivets (solid, cherry, hi-lok, hi-shear, flush, blind/pop) and mechanical fasteners using bucking bars, rivet guns, pullers, and torque tools to manufacturer-specified patterns and torque values.
Perform structural splice installations and repairs, including cold working and match-drilling to maintain structural load paths and FAA airworthiness compliance.
Conduct corrosion removal and treatment, including chemical processes, surface preparation, priming, and application of corrosion inhibitors according to aircraft corrosion control programs.
Execute metal-to-metal and metal-to-composite interface repairs, including trimming, edge finishing, and bonding preparation where applicable, while coordinating with composite technicians and engineering.
Use precision measuring instruments (micrometers, calipers, protractors, height gauges, dial indicators) to verify dimensional accuracy and maintain parts within tolerance on critical jet aircraft structures.
Make on-the-job modifications and field repairs during maintenance events and AOG situations with speed and accuracy while documenting deviations and obtaining engineering or inspector approvals when required.
Complete detailed work orders, repair tags, logbook entries, and non-conformance reports to ensure traceability and compliance with regulatory and quality management systems.
Coordinate with maintenance planners, engineers, quality assurance, and production teams to sequence structural work, secure parts, and ensure on-time delivery for scheduled heavy maintenance checks and modifications.
Follow FAA, EASA or other regulatory airworthiness directives, company procedures and quality standards for material traceability, certification of work, and final sign-off where authorized (A&P or company-authorized signatory).
Perform test fits and functional checks of control surface attachments, access panels, doors, and fastener systems to verify correct alignment and operation after structural repair or installation.
Maintain shop tooling and equipment, perform routine inspections, and report or repair defective tools promptly to avoid delays and ensure safety and quality.
Apply sealants, primers, and touch-up finishes to structural areas following repair to prevent corrosion and preserve aerodynamic surfaces as required.
Support modifications, STC installations, and structural retrofits, following engineering drawings and alteration instructions while ensuring weight and balance impacts are documented.
Train and mentor junior sheet metal technicians and apprentices in safe working practices, tool usage, rivet setting techniques, blueprint reading and aircraft-specific repair methods.
Participate in final inspections with QA/inspectors and assist with disposition of repaired structure, providing technical explanations and documentation to meet customer and regulatory requirements.
Troubleshoot recurring structural issues and recommend design or process improvements to engineering and continuous improvement teams to reduce rework and improve reliability on jet aircraft fleets.
Perform safe handling and disposal of hazardous materials used in corrosion control, chemical treatments and primers, and follow hot work and fire safety procedures in the hangar environment.
Support aircraft disassembly and reassembly during heavy maintenance checks, ensuring structural integrity and correct reinstallation of panels, fairings and flight-critical components.

Secondary Functions

Assist with inventory control of structural parts, fasteners, material certifications, and sheet stock to maintain a compliant parts supply for jet aircraft repairs.
Contribute to process documentation and standard work creation for common repairs and fabrication tasks to improve repeatability and training.
Support cross-functional teams (avionics, composites, systems) during baseline modifications and complex retrofits to ensure integrated installations meet structural requirements.
Participate in continuous improvement initiatives and lean manufacturing efforts to reduce cycle time for structural repairs in the hangar/shop environment.
Provide feedback to engineering on field repair feasibility and cost-effective repair alternatives for inclusion in SRMs or service bulletins.
Maintain a clean, organized, and safety-compliant work area; follow PPE and hangar safety policies and support periodic safety audits.

Required Skills & Competencies

Hard Skills (Technical)

Blueprint reading and interpretation specific to aircraft structural drawings and OEM repair data (SRM, structural drawings, DWGs).
Aircraft sheet metal fabrication: cutting, bending, flanging, forming, edge finishing and riveting to aerospace tolerances.
Riveting and fastening: experience with solid rivets (bucking), blind rivets, Hi-Lok/Hi-Shear fasteners and torque-controlled mechanical fasteners.
Precision measurement and layout: micrometers, calipers, protractors, height gauges, layout punches, and scribing for accurate fabrication and installation.
Metalworking machinery operation: press brakes, CNC brakes, rollers, shears, notchers, and drill presses geared for aviation parts.
Corrosion control and treatment, including chemical stripping, neutralization, and application of primers and corrosion inhibitors per maintenance manuals.
Structural repair processes: match drilling, cold working, splice plate installation, and repair of skins, ribs, frames, and longerons.
Familiarity with aircraft materials: aluminum alloys, stainless steel, titanium basics, and metal-to-composite interface considerations.
Non-Destructive Inspection (NDT) awareness: visual inspection, dye penetrant/fluorescent penetrant techniques and coordination with certified NDT personnel.
Regulatory and quality knowledge: FAA/EASA rules, airworthiness directives, work order documentation, material traceability and logbook entries.
Use of hand and power tools safely and effectively: pneumatic rivet guns, countersinks, deburring tools, grinders, and torque wrenches.
Welding awareness (beneficial): basic TIG/MIG welding knowledge where applicable for structure repairs or attachments.
Familiarity with maintenance planning systems and electronic work cards / computerized maintenance tracking (preferred).

Soft Skills

Meticulous attention to detail with strong focus on quality and airworthiness.
Problem-solving and analytical thinking to assess structural damage and determine correct repair methods.
Effective communication skills for coordination with engineers, QA inspectors, planners and teammates.
Strong time management and organizational skills to meet scheduled heavy maintenance windows and turnaround times.
Team-oriented mindset, able to mentor junior technicians and work collaboratively in multi-disciplinary teams.
Adaptability and ability to work under pressure in AOG and tight-deadline situations.
Safety-first attitude with commitment to follow PPE, hot work and hazardous material protocols.
Willingness to learn new techniques, OEM procedures, and tooling as aircraft technology evolves.
Professionalism and integrity in maintaining accurate documentation and complying with regulatory requirements.
Continuous improvement mindset to suggest process improvements that reduce rework and increase throughput.

Education & Experience

Educational Background

Minimum Education:

High school diploma or GED; vocational training or certificate in sheet metal, aircraft fabrication, or aircraft maintenance preferred.

Preferred Education:

FAA Airframe & Powerplant (A&P) certificate or equivalent national aviation maintenance license.
Certificate or diploma from an accredited Aerospace Sheet Metal or Aircraft Maintenance program.
Associate degree in Aviation Maintenance Technology or Manufacturing/Mechanical Technology (beneficial).

Relevant Fields of Study:

Aerospace/Aviation Maintenance Technology
Sheet Metal Fabrication / Metalworking Technology
Mechanical or Manufacturing Technology
Industrial Maintenance / Trade School Programs

Experience Requirements

Typical Experience Range: 2–8 years performing sheet metal repairs and fabrication on aircraft; jet aircraft experience strongly preferred.

Preferred:

3–5+ years of progressive experience working structural repairs on jet aircraft (narrowbody, widebody, business jets, or regional jets).
Experience with OEM procedures (Boeing, Airbus, Gulfstream, Bombardier, Embraer, etc.), SRMs, and FAA/EASA compliance.
Documented experience with rivet systems, precision fabrication, corrosion control, and final structural inspection sign-off procedures.