Key Responsibilities and Required Skills for Jet Fabrication Technician

🎯 Role Definition

A Jet Fabrication Technician is a skilled aerospace manufacturing professional responsible for fabricating, assembling, repairing, and finishing aircraft structural components and assemblies. This role requires expert interpretation of engineering drawings and specifications, hands-on proficiency with sheet metal, composite materials, fastening systems and fabrication equipment, and rigorous adherence to quality, safety, and regulatory standards (AS9100, NADCAP, FAA where applicable). The technician works closely with engineers, quality inspectors and production teams to deliver airworthy, precision components for jets and other aircraft.

📈 Career Progression

Typical Career Path

Entry Point From:

Sheet Metal Apprentice or Entry-Level Sheet Metal Fabricator
Aircraft Assembly Technician or Production Assembler
Vocational/Technical Program Graduate (Aerospace Manufacturing, Sheet Metal)

Advancement To:

Senior Jet Fabrication Technician / Lead Fabricator
Structural Repair Technician / Aircraft Structural Specialist
Production Supervisor / Fabrication Shop Lead
Manufacturing Engineer (with additional training) or Quality Assurance Specialist

Lateral Moves:

Composite Technician (autoclave and layup specialization)
Tooling & Fixtures Technician
NDT (Non-Destructive Testing) Technician

Core Responsibilities

Primary Functions

Interpret and accurately apply engineering drawings, blueprints, schematics and GD&T tolerances to fabricate complex jet airframe components, assemblies and structural subassemblies to required specifications and finish standards.
Precisely lay out, cut, shape and form sheet metal, aluminum, titanium and other aerospace alloys using hand tools, brakes, shears, rollers and CNC-controlled forming equipment while maintaining dimensional tolerances and minimizing material scrap.
Perform precision drilling, countersinking, dimpling and fastening operations (solid rivets, blind rivets, hi-locks, bolts) using pneumatic and manual rivet guns, torque wrenches and assembly jigs to achieve structurally sound and repeatable joints.
Execute composite layup, trimming, vacuum bagging, cure cycles and post-cure trimming for composite skins and components, following ply schedules, resin handling procedures and autoclave/oven profiles per engineering instructions.
Operate CNC punch, laser and waterjet cutting equipment, set up programs, and perform first-piece inspection to ensure consistent, accurate parts production and adherence to nested material layouts.
Fabricate and install precision structural fittings and brackets, ensuring correct hole locations, edge distances, and command of fastener selection in accordance with parts lists and structural load requirements.
Conduct in-process and final inspections using micrometers, calipers, height gauges, bore gauges and other precision measuring instruments, documenting measurements on inspection reports and nonconformance records where necessary.
Complete structural repairs including crack stop-drilling, patch installation, splice repairs, tear-down and reassembly of affected components, following repair schemes and obtaining required engineering or QA authorization.
Prepare and apply corrosion treatment, primer, sealants and protective coatings to structural surfaces, ensuring surface cleanliness, correct cure times and compliance with chemical handling and environmental controls.
Maintain and operate bench tools such as grinders, files, deburring tools and sanders to achieve required fit, finish and edge break specifications on fabricated components.
Disassemble and reassemble aircraft components and systems as directed for modification and retrofit installations, ensuring all fastener torque settings, safety wiring and hardware identification are documented and compliant.
Read and interpret engineering change orders (ECOs), service bulletins and modification drawings; implement changes in the shop and update traveler documents and build records to reflect current configuration.
Follow established work instructions, standard operating procedures and production travelers while contributing to lessons learned to improve fabrication processes and reduce cycle time.
Perform root cause analysis on repetitive manufacturing discrepancies, collaborate with engineering and quality teams to implement corrective actions and document effectiveness through follow-up inspections.
Ensure traceability of materials and parts by maintaining batch, lot and serial number records, logging material certificates and complying with NADCAP/AS9100 traceability requirements.
Participate in first article inspections (FAI), process qualification runs and product conformance verification, supporting Quality with required documentation and dimensional reports.
Train and mentor junior fabricators and apprentices on proper fabrication techniques, safe machine operation, blueprint reading and company quality expectations.
Maintain a clean, safe and organized work area, enforce PPE use and participate in safety audits, hazard analyses and continuous improvement safety initiatives.
Calibrate and care for precision measuring instruments and hand tools, report tool condition to supervision and request replacements or calibration as needed to support accurate fabrication.
Coordinate with sourcing and inventory teams to ensure availability of raw materials, fasteners, and consumables, assist in cycle counting and report material shortages that would impact production schedules.
Use basic CAD/CAM tools to review part features, verify hole patterns, and create simple fabrication fixtures or templates under engineering guidance for prototyping or low-volume builds.
Support shop-floor scheduling by estimating fabrication lead times, escalating issues that jeopardize deadlines and recommending alternate machining or assembly sequences to meet delivery targets.
Adhere to environmental, safety and hazardous material disposal regulations when handling chemicals, solvents and composite resins, including MSDS use and proper labeling of containers.
Prepare and maintain accurate build cards, traveler documents, inspection checklists and signoffs to ensure products are release-ready and audit-compliant.

Secondary Functions

Participate in continuous improvement initiatives such as 5S, Kaizen events and process mapping to streamline fabrication workflows, reduce waste and increase throughput.
Assist engineering with prototype builds, design-for-manufacturability (DFM) feedback and creation of permanent manufacturing work instructions based on hands-on fabrication experience.
Support non-destructive testing (NDT) activities by preparing surfaces, tagging parts and collecting dimensional and condition data for QA analysis.
Contribute to tooling design feedback and small fixture fabrication, helping to validate jigs and gauges for repeatable and accurate assembly processes.
Provide on-the-job coaching and formal training sessions to upskill team members on new equipment, materials and revised fabrication techniques.
Help maintain inventory accuracy by labeling received materials, rotating stock using FIFO methods and reporting discrepancies to purchasing or inventory control.
Assist with customer and internal audits by preparing required documentation, hosting auditors in the shop and executing corrective actions as directed by QA.
Participate in cross-functional meetings with procurement, planning and engineering to communicate capacity, tooling needs and potential lead-time impacts.

Required Skills & Competencies

Hard Skills (Technical)

Expert ability to read and interpret detailed aerospace engineering drawings, blueprints and GD&T callouts.
Proficiency in sheet metal fabrication techniques: bending, forming, shearing, rolling and edge finishing to aerospace tolerances.
Hands-on experience with rivet installation (solid, blind, structural), torque application, countersinking and dimpling for flush fastener installation.
Composite fabrication skills including ply layup, vacuum bagging, resin handling, cure cycle execution and post-cure trimming.
Competence operating CNC punching, laser, and waterjet cutting machines and ability to perform basic program setup and first-off verification.
Familiarity with machining basics, fixture set-up and the use of drill presses, mills, cold saws and band saws in support of part fabrication.
Strong inspection and metrology skills: calipers, micrometers, height gauges and coordinate measuring device (CMM) awareness or support.
Knowledge of aerospace quality systems and standards (AS9100, NADCAP processes) and experience producing documentation for First Article Inspection (FAI).
Experience with surface treatments: corrosion control, priming, sealant application, chemical etching and handling of hazardous materials with MSDS compliance.
Basic CAD/CAM literacy (e.g., reading models in SolidWorks, NX or similar) and capability to validate part geometry for shop processes.
Familiarity with non-destructive testing methods (dye penetrant, fluorescent penetrant, visual inspection) and preparation for NDT.
Proficient use of hand and power tools, pneumatic tooling, rivet guns, torque equipment and safety interlocks common to fabrication shops.

Soft Skills

Strong attention to detail with a commitment to producing defect-free components and maintaining traceability.
Excellent communication skills to collaborate with engineers, quality inspectors and production planners.
Problem-solving orientation to analyze fit-up issues, suggest corrective actions and implement engineering-approved fixes.
Time management and organizational abilities to manage multiple build cards and priorities in a production environment.
Team player mindset with willingness to train others and accept feedback to continuously improve skills.
Adaptability to changing work instructions, shift priorities and fast-paced manufacturing demands.
Safety-first attitude with consistent adherence to PPE, lockout/tagout and shop safety protocols.
Reliability and accountability for meeting schedule commitments and quality standards.
Continuous learning orientation to stay current with new materials, tooling and fabrication technologies.
Professional disposition for dealing with internal and external customers during audits and build reviews.

Education & Experience

Educational Background

Minimum Education:

High School Diploma or GED with relevant vocational or on-the-job training in sheet metal work or aircraft fabrication.

Preferred Education:

Associate degree or technical certificate in Aerospace Manufacturing, Sheet Metal Technology, Welding, or a related trade program.
FAA Airframe & Powerplant (A&P) certification, IPC or NADCAP-related training is advantageous but not always required.

Relevant Fields of Study:

Aerospace Manufacturing Technology
Sheet Metal Fabrication and Welding
Composite Materials and Processes
Industrial Maintenance / Precision Machining

Experience Requirements

Typical Experience Range: 2–7 years of hands-on fabrication experience in aerospace, aviation maintenance, or precision manufacturing.

Preferred:

3+ years fabricating jet or commercial aircraft structural components and assemblies.
Demonstrated experience with AS9100 / NADCAP shop environments, first article inspections, and working with engineering change orders and repair schemes.
Prior experience mentoring or leading small teams and participating in continuous improvement initiatives.