Key Responsibilities and Required Skills for Jet Engine Builder

🎯 Role Definition

A Jet Engine Builder (also titled Turbine Engine Assembler or Jet Engine Technician) assembles, inspects, troubleshoots and tests turbine engine components and complete engine assemblies to manufacturer and regulatory standards. The role requires precision mechanical assembly, interpretation of technical documentation (AMM, IPC, engineering drawings), application of non-destructive testing (NDT) methods, rotor balancing, and documentation/compliance with FAA/EASA quality systems. The Jet Engine Builder works closely with engineering, quality, supply chain and test cell teams to deliver safe, airworthy engines and components.

📈 Career Progression

Typical Career Path

Entry Point From:

Aircraft Mechanic (A&P / AMT) with turbine experience
Machinist or Tool & Die Technician transitioning into aerospace assembly
Military Aviation Technician (engine/propulsion specialist)
Sheet Metal or Structures Technician moving into engine shop

Advancement To:

Lead Jet Engine Builder / Lead Assembler
Engine Overhaul Supervisor or Cell Supervisor
Test Cell Technician / Engine Test Supervisor
Quality Engineer (specializing in engine QA)
Field Service Engineer / On-wing Support Technician
Production or Maintenance Manager

Lateral Moves:

Non-Destructive Testing (NDT) Technician
Rotor Balancing Specialist / Vibration Analyst
Maintenance Planner / Technical Publications Specialist
Component Repair / Tooling Specialist

Core Responsibilities

Primary Functions

Perform complete turbine engine assembly and build-up: install compressors, combustors, turbines, accessory gearboxes, shafts, bearings, seals and casings per OEM assembly procedures, assembly drawings, AMM (Aircraft Maintenance Manual) and IPC (Illustrated Parts Catalog), ensuring correct part serializations and traceability.
Interpret and apply engineering drawings, detailed tolerances, fit-up instructions and torque sequences to achieve precise assemblies; adjust clearances and fits to OEM specifications using calibrated measuring equipment.
Conduct precision measurements and dimensional inspections for fit, runout and concentricity using micrometers, calipers, bore gauges, dial indicators, height gauges and coordinate measuring devices; document results and escalate deviations.
Install and set bearings, seals, and press-fit components using hydraulic and arbor presses, fixtures, fixtures, mandrels and specialized tooling; control interference fits and lubrication per engineering instructions.
Perform rotor balancing and dynamic/static balancing operations on rotors, spools and assemblies using balancing machines and vibration analyzers; interpret balancing reports and make corrective actions to meet vibration limits.
Apply non-destructive testing techniques (borescope inspections, fluorescent penetrant inspection (FPI), magnetic particle inspection (MPI), eddy current where applicable) to detect cracks, foreign object damage (FOD) and discontinuities; record and report findings per quality procedures.
Assemble and install fuel systems, oil systems, fuel nozzles and accessory components, ensuring leak-free connections, correct clearances and functional checks prior to engine run.
Carry out pre-test assembly checks and prepare engine for test cell runs: install instrumentation, thermocouples and pressure transducers; connect data acquisition systems and verify electrical/flight control interfaces for safe testing.
Support engine ground runs and test cell operations by monitoring instrumentation, recording test parameters, making live adjustments and responding to abnormal indications under supervision of test engineers.
Disassemble, inspect, and evaluate turbine engine components during overhaul: perform borescope and visual inspections, measure wear limits, and complete first article inspections and disposition of parts based on OEM limits.
Execute removal and replacement of blades, vanes, seals and shrouds including exact torqueing, staking, locking wire/locking features, and application of specified adhesives and sealants per technical data.
Follow strict contamination control and cleanliness protocols (clean room procedures for critical surfaces, bagging/flushing, particulate control) to prevent FOD and preserve engine integrity.
Utilize SAP, MRP, MES or PLM systems to process work orders, update serial records, complete electronic signoffs, log deviations and maintain full configuration control of engine and components.
Complete and maintain accurate build documentation, inspection records, non-conformance reports (NCR), serviceable taggings, and return-to-service paperwork consistent with FAA/EASA regulations and internal quality systems.
Perform component rework and repair per engineering disposition and repair manuals, including removal and replacement of plated components, application of coatings, and execution of approved rework processes.
Participate in root cause investigations and corrective action implementation (CAPA) for assembly-related failures, contributing hands-on feedback and improvement suggestions to engineering and quality teams.
Maintain and calibrate specialized tooling and test equipment, ensuring tools are tagged, calibrated and stored properly. Report tool damage or out-of-cal specification tools immediately.
Ensure personal and team compliance with workplace safety programs, hazardous materials handling, environmental controls and PPE requirements; follow lockout/tagout and LOTO procedures during disassembly and rigging.
Train, mentor and coach junior assemblers and apprentices on best practices, troubleshooting techniques, torqueing and measurement methods, and company-specific assembly standards.
Collaborate with purchasing and supply chain to identify obsolete, damaged or missing parts, recommend alternatives per engineering, and expedite critical parts to sustain engine assembly schedules.
Implement lean manufacturing and continuous improvement ideas in the shop floor: reduce cycle time, improve first-pass yield, standardize work instructions and document best practices for repeatable engine builds.
Perform hands-on troubleshooting of subsystem faults (oil, fuel, ignition, accessory drives) using schematic diagrams and test procedures; isolate root cause and perform corrective repairs or recommend engineering actions.
Support field service and on-wing maintenance activities as required, including travel to customer sites to assist with complex engine removal, installation and on-site repairs under company procedures and safety policies.
Ensure cross-functional communication with engineering change management to incorporate Service Bulletins, Engineering Orders and OEM updates into build procedures and daily work execution.

Secondary Functions

Support continuous improvement initiatives by contributing to Kaizen events, process documentation updates and time-study analyses for engine assembly tasks.
Assist with special projects such as new engine introduction (NEI) kits, tooling validation, first articles and pilot production runs, providing feedback to design and manufacturing engineering.
Participate in safety, quality and production meetings, providing status updates on engine build progress, quality metrics and potential schedule risks.
Help maintain inventory control for consumables, fasteners and sealing materials used in engine builds; report shortages and participate in root cause analysis for recurring inventory discrepancies.
Collaborate with engineering and quality to qualify alternate suppliers, new materials and vendor repairs through testing and documentation validation as required.
Create or update work instruction job aids and training packages to reflect process improvements, OEM updates and company best practices.
Support ad-hoc technical requests (e.g., tooling design modifications, special gauges) and prototype assembly tasks to enable continuous product improvement and faster turnarounds.

Required Skills & Competencies

Hard Skills (Technical)

Proficient reading and interpreting engineering drawings, geometric tolerancing (GD&T), specifications, AMM and IPC documents relevant to turbine engines.
Hands-on experience assembling turbine engines, compressors, turbines, accessory gearboxes and related subsystems to OEM procedures.
Precision measurement skills: micrometers, calipers, bore gauges, dial indicators, height gauges, and basic use of CMM or portable metrology tools.
Rotor balancing, vibration analysis and experience using balancing machines and analyzers to meet OEM vibration limits.
Non-Destructive Testing knowledge and practical use (borescope inspection, FPI, MPI) and ability to document and interpret results.
Familiarity with torqueing tools, torque-angle procedures, torque wrenches, hydraulic presses and staking/locking techniques.
Experience with engine test cell operations, instrumentation setup, data acquisition and interpreting test run data.
Competency with ERP/MES/PLM systems (SAP, Oracle, Teamcenter, Siemens, or equivalent) for serial tracking and work order management.
Knowledge of FAA/EASA regulations, quality systems, airworthiness documentation, service bulletins and technical directives that affect engine assembly and return-to-service.
Proficiency applying anti-seize, adhesives, sealants and thread-locking compounds per technical data and contamination control procedures.
Competency in using hand and power tools safely and in compliance with shop procedures and tool calibration programs.
Experience performing component repair, rework and disposition following OEM repair manuals and engineering dispositions.
Basic electrical and instrumentation understanding sufficient for engine instrumentation hookup and functional checks.
Use of personal and shop-level calibration systems to verify tooling; familiarity with calibration records and tool tags.

Soft Skills

Extreme attention to detail, patience and steady hands for high-precision assembly work.
Strong troubleshooting and analytical thinking to diagnose assembly and test issues and propose corrective actions.
Clear verbal and written communication skills — able to complete accurate build records and communicate with engineers and inspectors.
Teamwork and cross-functional collaboration: works closely with quality, engineering, supply chain and test cell personnel.
Time management and ability to prioritize tasks in a production/overhaul environment with competing deadlines.
Continuous improvement mindset: open to process improvement, documenting best practices and mentoring others.
Adaptability and willingness to work shifts, overtime or travel for field service assignments if required.
Accountability and integrity in maintaining accurate paperwork, serial traceability and regulatory compliance.
Strong manual dexterity and physical stamina for lifting, positioning heavy components using hoists and working in confined spaces.
Safety-first mentality, commitment to following all shop safety programs and hazardous material handling rules.

Education & Experience

Educational Background

Minimum Education:

High school diploma or GED with vocational training in aircraft maintenance, machining or mechanical assembly.

Preferred Education:

Associate degree or technical diploma in Aerospace Technology, Aviation Maintenance Technology, Mechanical Engineering Technology, or related discipline.
FAA A&P certification (preferred in the U.S.) or equivalent aviation maintenance qualifications; military aviation maintenance experience highly regarded.

Relevant Fields of Study:

Aerospace Technology
Aviation Maintenance & Repair (A&P)
Mechanical Engineering Technology
Precision Machining / Tooling
Industrial Maintenance / Mechatronics

Experience Requirements

Typical Experience Range: 2–8 years of hands-on experience assembling and overhauling turbine engines or working in a gas-turbine engine overhaul/repair facility.

Preferred:

5+ years of direct experience assembling, overhauling or testing commercial or military turbine engines.
Prior experience working with OEM engine models (e.g., Rolls-Royce, GE, Pratt & Whitney) or in an FAA/EASA regulated repair station environment.
Demonstrated experience with rotor balancing, borescope inspection and test cell support.