Key Responsibilities and Required Skills for Jet Repair Machinist

🎯 Role Definition

A Jet Repair Machinist is a highly skilled manufacturing and maintenance professional who performs precision repair, modification, and rebuilding of aircraft engine components (rotors, stators, shafts, turbine blades, casings, and accessory gearboxes). The role requires advanced machining, welding/brazing, NDT inspection, blueprint/GD&T interpretation, and strict adherence to aviation quality and regulatory standards (FAA, EASA, OEM repair manuals). The Machinist works in a Maintenance, Repair and Overhaul (MRO) environment to restore serviceability and extend life of high-value jet engine parts while supporting shop throughput, safety, and quality objectives.

📈 Career Progression

Typical Career Path

Entry Point From:

CNC Machinist or Manual Machinist (precision manufacturing shop)
Aircraft Maintenance Technician / A&P Mechanic seeking shop specialization
Tool & Die Maker or Mechanical Technician with aerospace exposure

Advancement To:

Senior Jet Repair Machinist / Lead Machinist
Engine Shop Supervisor or Repair Cell Lead
Quality/Inspection Lead or NDT Supervisor
MRO Program Manager or Maintenance Engineering Specialist

Lateral Moves:

NDT Technician (fluorescent penetrant, eddy current, ultrasonic)
Tooling & Fixtures Engineer / CNC Programmer
Field Service Technician (engine run, installation, troubleshooting)

Core Responsibilities

Primary Functions

Disassemble, inspect, diagnose, and document defects in jet engine components (compressor/turbine blades, shafts, casings, seals, bearings) using borescope inspection, micrometers, calipers, dial indicators, and other precision measuring tools to determine repairability to OEM tolerances.
Interpret engineering drawings, OEM repair manuals, service bulletins, and GD&T callouts to develop and execute accurate repair plans that meet FAA/EASA and customer requirements.
Perform precision machining operations on jet engine parts using manual lathes, milling machines, surface grinders, cylindrical grinders, and CNC equipment to restore dimensional accuracy and surface finishes per blueprint specifications.
Set up and operate CNC turning and milling centers, perform program edits, select tooling and cutting parameters, and verify first-piece measurements to ensure compliance with technical data.
Conduct welding, brazing, thermal spray, or laser cladding repairs on turbine blades, vanes, shrouds, and housings using aerospace-approved processes (TIG, MIG, braze, composite patching) for nickel and titanium alloys.
Execute mechanical and thermal stress-relief treatments, heat-treat operations coordination, and follow-up dimensional checks to stabilize repaired components and meet metallurgical requirements.
Perform non-destructive testing (NDT) inspections — fluorescent penetrant, eddy current, magnetic particle, and ultrasonic testing — to detect cracks, subsurface defects, and material discontinuities before and after repair.
Balance rotating assemblies and rotors using dynamic balancers; document balance corrections and verify vibration limits meet OEM and shop acceptance criteria.
Repair and refinishing of blade and vane edges, tip grinding, coating removal, and application of corrosion protection and surface treatments to meet aerodynamic profile and durability standards.
Remove, recondition, and replace bearings, seals, and fasteners while documenting torque, fit, and run-out per maintenance instructions and service limits.
Troubleshoot complex repair issues and coordinate engineering dispositions (MRB/MRO repair approvals) with OEMs, quality engineering, and maintenance engineering to secure approvals and alternate repair methods when necessary.
Create and maintain accurate shop orders, repair tags, logbooks, work cards, and electronic maintenance records in ERP/MRO systems (e.g., SAP, IFS, AMOS) to ensure traceability and regulatory compliance.
Calibrate and verify precision measuring instruments and gauges prior to use; maintain tool calibration records and participate in instrument audits.
Fabricate and maintain custom tooling, fixtures, and soft jaws for one-off or low-volume engine component repairs; collaborate with tooling engineers to improve fixturing designs.
Conduct first article inspections and final acceptance inspections on repaired components; prepare and issue inspection reports, certification paperwork, and sign-offs in accordance with quality system procedures.
Participate in engine teardown and reassembly processes in coordination with engine mechanics and field service personnel, ensuring repaired components are installed and torqued to specification.
Estimate repair time and material costs, prepare job travelers, and communicate lead-time and material needs to production planners and procurement to support on-time delivery.
Adhere to hazardous materials handling and shop safety procedures, maintain clean and organized work areas, and ensure proper use of PPE while supporting environmental and safety compliance.
Mentor, train, and cross-train junior machinists and apprentices on engine repair techniques, inspection criteria, and shop best practices to build team capability.
Support root cause analysis investigations for repeat failures, contribute corrective actions, and update repair instructions or standard work to reduce rework and improve reliability.
Participate in quality and regulatory audits, provide technical evidence and process demonstrations, and implement corrective actions stemming from audit findings.
Maintain up-to-date knowledge of OEM service bulletins, airworthiness directives (ADs), and evolving repair techniques for new engine models and materials.

Secondary Functions

Collaborate with production planning to prioritize repair queues, reduce bottlenecks, and meet customer turnaround time commitments.
Support continuous improvement initiatives (Lean, 5S, Kaizen) to optimize shop flow, reduce waste, and increase throughput for engine component repairs.
Assist in inventory management of repair parts, raw stock (titanium, Inconel, stainless), abrasives, and consumables; raise purchase requisitions and track small-batch orders.
Coordinate with quality, logistics, and shipping/receiving to ensure timely delivery of repaired components and proper packaging per shipping regulations.
Provide technical input to quotations and job estimates; review and refine standard repair prices and labor standards based on real shop performance.
Support shop test cell operations by preparing components for run-in, monitoring performance parameters, and documenting test results.
Help maintain calibration schedules, tooling inventories, and maintenance logs; escalate equipment issues to maintenance or engineering support teams.
Assist customers and field service teams with repair status updates, technical clarifications, and disposition of non-conforming parts.
Participate in training programs to stay current with new machining technology, NDT methods, and emerging materials in the aerospace sector.
Contribute to development and revision of standard operating procedures (SOPs), work instructions, and training materials for complex repair processes.

Required Skills & Competencies

Hard Skills (Technical)

Precision machining (manual and CNC turning, milling, grinding) on metal alloys used in jet engines (Inconel, titanium, stainless steels).
Blueprint reading, geometric dimensioning & tolerancing (GD&T), and ability to interpret OEM technical data and repair manuals.
Non-destructive testing (NDT) experience: fluorescent penetrant (FPI/ MPI), eddy current (ECT), ultrasonic testing (UT), and borescope inspection.
Aerospace welding, brazing, and thermal spray repair techniques (TIG, braze, laser cladding) on high-temperature alloys.
Use and interpretation of precision measuring instruments: micrometers, calipers, height gauges, dial indicators, profilometers, and CMM operation familiarity.
Rotor/rotating assembly balancing and vibration mitigation techniques, including dynamic balancer operation and documentation.
Experience with engine shop software and ERP/MRO systems (e.g., SAP, IFS, AMOS) for work order tracking and part traceability.
Knowledge of heat treat processes and metallurgy basics for nickel and titanium alloys, including stress relief and tempering considerations.
MRB/MRO disposition process knowledge, familiarity with FAA/EASA regulations, and experience preparing airworthiness documentation.
Fixture and tooling fabrication for low-run aerospace repairs; ability to design temporary soft jaws and bespoke holds for precision operations.
Skill in finishing processes: surface grinding, tip grinding, polishing, and applying protective coatings and corrosion inhibitors.
Troubleshooting and root cause analysis for recurring component failures using structured problem-solving methodologies.

Soft Skills

Strong attention to detail and quality-first mindset to ensure safety and regulatory compliance for critical engine components.
Excellent problem-solving skills, ability to analyze failures and implement durable corrective actions.
Clear verbal and written communication to document work, coordinate with engineers, QA, and customers, and prepare repair reports.
Team player with the ability to mentor junior technicians and collaborate across production, engineering, and quality functions.
Time management and prioritization skills to manage multiple repair jobs while meeting turnaround time commitments.
Adaptability to work with new engine models, advanced materials, and evolving repair technologies.
Commitment to continuous improvement and participation in Lean/5S activities to increase shop efficiency.
Strong organizational skills for maintaining tooling, calibration records, and traceability documentation.
Professionalism when interfacing with customers, field teams, and regulatory auditors.
Safety-conscious mindset and disciplined adherence to PPE, hazardous material handling, and shop safety rules.

Education & Experience

Educational Background

Minimum Education:

High school diploma or GED plus vocational/technical certificate in machining, industrial maintenance, or aerospace technology.

Preferred Education:

Associate degree in Machining Technology, Aerospace Maintenance, Manufacturing Engineering Technology, or related field.
FAA A&P certificate or equivalent aerospace maintenance certification is a strong plus for candidate mobility.

Relevant Fields of Study:

Machining / Tool & Die Technology
Aerospace Maintenance / Aviation Technology
Manufacturing Engineering / Industrial Technology
Materials Science / Metallurgy

Experience Requirements

Typical Experience Range: 3–7 years of precision machining and component repair experience in an aerospace or MRO environment.

Preferred:

5+ years of hands-on experience repairing jet engine components or working in an engine shop with documented FAA/EASA/MRO traceability and MRB participation.
Demonstrated experience with NDT, welding/brazing on aerospace alloys, CNC setup/programming for repair work, and use of ERP/MRO systems.
Prior exposure to OEM repair specifications, ADs, service bulletins, and participation in audit/certification processes.