Key Responsibilities and Required Skills for Jet Composite Technician

🎯 Role Definition

The Jet Composite Technician is a hands-on aerospace manufacturing specialist responsible for producing, assembling and repairing advanced composite structures for business and commercial jets. Working to engineering drawings, process specifications and safety standards (AS9100/NADCAP where applicable), this role performs prepreg layup, vacuum bagging, autoclave operations, structural bonding and nondestructive inspection while documenting work to stringent quality and traceability requirements. The ideal candidate combines deep materials knowledge with meticulous process control, strong communication, and a continuous-improvement mindset.

📈 Career Progression

Typical Career Path

Entry Point From:

Composite Technician Apprentice / Trainee
Aircraft Assembler or Manufacturing Assembler
Aviation Maintenance Technician (A&P) transitioning to composites

Advancement To:

Senior Composite Technician / Lead Technician
Composite Repair Specialist or NDT Technician
Production Supervisor / Shop Foreman
Process Engineer / Materials Engineer

Lateral Moves:

Quality Inspector (Aerospace)
Tooling & Fixtures Technician
Bonding & Adhesives Specialist

Core Responsibilities

Primary Functions

Read, interpret and follow engineering drawings, dimensional prints, specifications and ply-books to perform precision hand layup, drape and ply sequencing for prepreg and wet-lay composite components for business jets and regional aircraft.
Prepare composite materials and tooling: cut pre-preg tapes/plies, core materials, peel-plies and release films using knives, die-cutters and CNC cutting tables while maintaining accurate waste and batch traceability.
Execute vacuum bagging and debulking operations, including placement of bleeder/porous materials and correct vacuum porting, to control resin flow and void content during cure cycles.
Operate, monitor and document autoclave cure cycles, including pressure ramping, dwell profiles and temperature verification logs; perform oven cures and wet cure processes according to work instructions.
Perform resin infusion and RTM (resin transfer molding) set-up and processing, including resin dosing, bleed control, gel times and post-cure handling to meet structural requirements.
Build and assemble subcomponents using precisely executed adhesive film bonding, secondary bonding and fastener installation techniques while maintaining surface prep and cleanliness per procedures.
Trim, drill, countersink and finish composite parts using routers, saws and portable tools; install metal inserts, bushings and fasteners to close-tolerance specifications.
Conduct structural composite repairs to OEM and SRM repair manuals (scarf, patch, stitch-and-bond) including surface prep, fit-checks, cure cycles and restoration of structural integrity.
Perform nondestructive inspection (NDT) methods—ultrasonic inspection (UT), fluorescent penetrant (FPI), tap testing and visual inspection—to identify delaminations, voids, porosity and other defects; document and disposition findings.
Complete in-process and final inspections against inspection criteria; create and maintain traveler documentation, production reports, lot numbers and traceability records to conform with AS9100/NADCAP standards.
Apply and verify adhesive mixing ratios, dispense adhesives and sealants, and control cure times and temperatures for structural bonds and secondary joints.
Set up, maintain and fine-tune jigs, fixtures and tooling for repetitive composite layup processes; perform tool maintenance and communicate tool wear or damage to tooling engineering.
Follow chemical handling, hazardous materials and safety protocols for epoxies, solvents and release agents; use PPE and maintain cleanroom or controlled-environment practices as required.
Troubleshoot process variances such as resin rich/lean conditions, ply misalignment, cure anomalies and vacuum leaks; implement corrective actions and escalate complex issues to engineering.
Participate in first-article inspections, in-process audits and support nonconformance investigations by providing technical detail, containment actions and suggested corrective measures.
Maintain dimensional control using hand gauges, calipers, micrometers and coordinate with CMM operators for verification of critical features and hole patterns.
Support manufacturing change implementation by validating process documentation, updating work instructions and training impacted operators on new procedures.
Collaborate with engineering, quality and production planning to optimize build sequences, reduce rework and improve first-pass yield on composite components.
Train and mentor junior technicians and apprentices on composite best practices, tooling use, layup techniques and quality expectations; contribute to standardized work and skills matrices.
Participate in continuous improvement initiatives (Lean, 5S, Kaizen) to reduce cycle times, waste and scrap while improving safety and product quality.
Maintain inventory control of composite materials and consumables, rotate stock to FIFO, inspect incoming material certificates and report irregularities to materials management.
Prepare parts for final assembly and hand-off to avionics/structure teams, including surface finishing, masking and protective packaging for shipment or subsequent operations.

Secondary Functions

Assist engineering with process validation trials and small prototype builds requiring hands-on composite expertise.
Support tooling changeovers and line balancing activities to minimize downtime during product transitions.
Provide subject-matter input for Work Instructions (WIs), standard operating procedures (SOPs) and training materials for composite processes.
Participate in safety and quality audits, corrective action implementation and supplier nonconformance investigations when related to composite materials or processes.
Maintain cleanliness and environmental controls in the layup and cure areas, including spill control, waste disposal and chemical inventory reconciliation.
Support ERP/MRP data entry for completed builds, material consumption and scrap documentation to ensure accurate production records.
Assist with customer or regulatory inspections by providing work documentation, process explanations and traceability of repaired or produced components.
Perform routine maintenance on composite manufacturing equipment and minor fixture repair to ensure continuous safe operation.

Required Skills & Competencies

Hard Skills (Technical)

Expert ability to read and interpret engineering drawings, ply-books, GD&T and dimensional tolerances.
Proficient in prepreg hand-layup, wet-layup and ply cutting with strict ply sequence adherence.
Vacuum bagging, debulking and autoclave/oven cure operation and documentation expertise.
Resin infusion (RTM/VARTM) setup and monitoring, including resin flow, bleed and venting control.
Structural composite repair skills: scarfing, patching, bonded repairs per OEM/SRM guidelines.
Nondestructive inspection experience: ultrasonic testing (A-scan/ phased array familiarity), tap testing and fluorescent penetrant inspection.
Adhesive bonding, film adhesive application, mixing ratios and cure control for structural joins.
Proficient in precision trimming, drilling, countersinking and fastener installation on composites.
Familiarity with AS9100, NADCAP process requirements and aerospace quality systems.
Hands-on experience with composite tooling, fixtures, layup tables and cleanroom protocols.
Measurement and inspection tools: calipers, micrometers, thickness gauges, torque tools and coordinate measuring devices.
Experience maintaining traveler documentation, batch records, material certifications and traceability.
Use of basic shop software/ERP systems for production reporting and material pulls.
Knowledge of hazardous chemical handling, MSDS interpretation and PPE usage for epoxy/solvent safety.
Ability to read cure charts and process control charts; basic SPC (statistical process control) awareness.

Soft Skills

Impeccable attention to detail and strong quality-first mindset.
Clear verbal and written communication with production, engineering and quality teams.
Problem-solving orientation with the ability to diagnose root causes and implement corrective actions.
Strong manual dexterity, steady hand and visual acuity for fine composite work.
Time management and ability to meet production schedules in a high-mix, low-volume environment.
Team player who supports cross-functional collaboration and training of junior staff.
Adaptability to changing priorities, new processes and tight delivery schedules.
Professional accountability, ownership of work quality and commitment to continuous improvement.
Ability to follow strict process and safety protocols consistently.
Mentoring and coaching ability to elevate team skill levels while preserving throughput.

Education & Experience

Educational Background

Minimum Education:

High school diploma or equivalent with vocational/commercial training in composite manufacturing or aviation maintenance.

Preferred Education:

Associate degree or technical diploma in Composite Materials Technology, Manufacturing Technology, Aviation Maintenance, or related field.

Relevant Fields of Study:

Aerospace Manufacturing Technology
Composite Materials & Processes
Aviation Maintenance Technology
Mechanical or Materials Engineering Technology

Experience Requirements

Typical Experience Range: 2 – 7 years in aerospace composite manufacturing or repair for business/commercial aircraft.

Preferred: 3+ years' demonstrated experience with prepreg layup, vacuum bagging and autoclave curing on composite primary or secondary aircraft structures; experience with SRM repair methods, NDT inspection and working under AS9100/NADCAP quality systems preferred.

Certifications such as NADCAP process familiarity, FAA A&P (beneficial), and manufacturer-specific composite repair training are advantageous.