Key Responsibilities and Required Skills for Jet Sheet Metal Assembler

🎯 Role Definition

A Jet Sheet Metal Assembler is a skilled technician responsible for the precise fabrication, assembly, and repair of metallic aircraft structures and components. This role combines blueprint interpretation, precision fitting, riveting and fastening, nondestructive inspection support, and adherence to aerospace quality and safety standards to ensure structural integrity and airworthiness of jet aircraft parts. The ideal candidate demonstrates meticulous attention to detail, strong knowledge of sheet metal processes, and experience working with aerospace alloys and assembly tooling.

📈 Career Progression

Typical Career Path

Entry Point From:

Sheet Metal Apprentice or Trainee with hands-on shop experience
Aircraft Structural Technician or Production Assembler from general manufacturing
Vocational certificate or community college program graduate in sheet metal technology

Advancement To:

Senior Jet Sheet Metal Assembler / Lead Assembler
Jig & Fixture Specialist or Tooling Coordinator
Quality Inspector (NDT/FAA-focused) or Quality Assurance Technician
Manufacturing Supervisor or Production Manager

Lateral Moves:

Composite Technician (airframe composites)
Aircraft Systems Assembler (avionics, flight control systems)

Core Responsibilities

Primary Functions

Read, interpret and execute complex aircraft blueprints, engineering drawings, and manufacturing specifications to correctly lay out, mark and cut sheet metal parts for jet airframe structures.
Precisely measure, shear, bend, form and trim aluminum, titanium and stainless steel parts using brake presses, shears, rollers and hand tools to meet dimensional tolerances required for aircraft assemblies.
Fit and match components, perform trial assemblies, and adjust mating parts to ensure proper alignment and gap control prior to drilling and fastening.
Drill, countersink, dimpling and ream holes to specification and prepare parts for fastening using power and hand tools in accordance with engineering standards.
Install aircraft fasteners, rivets (solid, blind, structural), bolts and mechanical lock joints using pneumatic and hand riveting tools while ensuring correct head form and grip, and verifying pull test results where required.
Execute precision flush and protruding rivet installations, including bucking for solid rivets and installation of Hi-Lok/Monogram/PEM hardware per manufacturer and company standards.
Perform edge preparation, deburring, chamfering and finishing of fabricated parts to remove burrs and sharp edges that could compromise fit or safety.
Use precision measuring instruments (micrometers, calipers, CMM input, height gauges and optical comparators) to verify part dimensions and produce required inspection records.
Interpret engineering change notices (ECNs), revision notes and non-conformance reports (NCRs) and implement drawing updates in current assemblies.
Lay out and fabricate light-gauge and complex sheet metal subassemblies for control surfaces, access panels, ducts, fairings and interior structural components.
Assemble and torque structural fasteners to specified values, using calibrated tools and documented torque procedures, and record results per process requirements.
Disassemble and repair corroded or fatigued sheet metal structure following repair manuals and FAA or company repair schemes, assuring airworthiness upon reassembly.
Follow and complete required inspection documentation, traveler sheets, manufacturing work orders and special process logs to maintain traceability and compliance.
Participate in and support non-destructive testing (NDT) such as dye penetrant or visual inspections by preparing parts and documenting indications for engineering disposition.
Collaborate with engineers and quality personnel to troubleshoot fit, finish or structural anomalies and propose corrective fabrication or assembly solutions.
Set up and operate machine tools and CNC shear/bend equipment as required for low to medium volume production runs, maintaining tooling offsets and production records.
Perform final assembly checks, gap verification, and structural fit-up for wing, fuselage sections and other major assemblies to ensure conforming builds for jigs and fixtures.
Ensure proper use of sealants, adhesives and surface preparation materials when instructed by engineering drawings or structural bonding procedures.
Maintain and calibrate hand tools, fixtures and gauges; report and tag out-of-tolerance tooling to prevent use until corrected.
Train, mentor and provide hands-on guidance to junior assemblers and apprentices on standard sheet metal practices and company fabrication procedures.
Follow and enforce safety procedures including handling of hazardous materials, use of personal protective equipment (PPE), lockout/tagout and shop housekeeping to maintain a safe shop floor.
Conduct first article inspections and support production quality audits to verify process capability and adherence to customer specifications.
Support continuous improvement initiatives by identifying process inefficiencies, suggesting tooling or workflow enhancements, and participating in root cause investigations of recurring defects.
Maintain an accurate Bill of Materials (BOM) verification and ensure parts are kitted and tracked to the appropriate work order and serial number.
Adapt to shift schedules and cross-functional workstations as required for production demands and delivery schedules.

Secondary Functions

Maintain up-to-date knowledge of FAA regulations, customer-specific requirements and industry best practices for aircraft structural assembly.
Support shop-floor inventory management by reporting low stock of raw materials, fasteners and special tools; assist with cycle counting as needed.
Contribute to documentation and standard work development for recurring assemblies to improve training and reduce variability.
Assist engineering with prototype assembly, route feedback and manufacturability assessments for new parts or design changes.
Participate in lean manufacturing and 5S activities to optimize workspace layout, reduce waste and improve throughput.

Required Skills & Competencies

Hard Skills (Technical)

Expert blueprint and engineering drawing interpretation including GD&T, tolerancing, and material callouts specific to aerospace production.
Precision measuring and metrology: micrometers, calipers, height gauges, dial indicators, and familiarity with coordinate measuring concepts.
Hand and power tool proficiency: pneumatic rivet guns, bucking bars, countersinks, drills, pneumatic shears and portable reamers.
Riveting and fastening expertise: solid rivets, blind rivets (Hi-Lok, CherryMax), bolts, nuts, lockwire and structural fastener installation procedures.
Sheet metal forming and layout: brake press operation, bending, rolling, stretch forming and cold working techniques for aerospace alloys.
Drilling, countersinking, dimpling and reaming techniques with attention to hole quality and edge conditions.
Basic CNC and brake press setup knowledge, including tooling selection and bend allowance calculations.
Corrosion control and repair practices for aluminum and mixed-metal assemblies, including proper surface prep and compatibilizers.
Familiarity with NDT support processes (visual inspection, dye penetrant) and ability to recognize possible indications requiring escalation.
Reading and implementing engineering change orders (ECO/ECN) and updating work instructions accordingly.
Use of torque wrenches, calibrated tools and completion of torque documentation per procedure.
Hands-on experience with aerospace adhesives, sealants and bonding processes where applicable.
Basic computer literacy: work order systems, electronic travelers, and digital markups (PDF/XLF) for drawing revisions.
Knowledge of FAA or equivalent civil aviation authority maintenance, repair and overhaul (MRO) documentation requirements is a plus.
Experience with assembly jigs, fixtures and temporary fastener systems used in airframe construction.

Soft Skills

Strong attention to detail and a personal commitment to quality and safety that prevents rework and contributes to airworthiness.
Effective verbal and written communication skills for working with engineers, quality inspectors and cross-functional teams.
Problem-solving mindset with the ability to diagnose fit and alignment issues and to implement practical, documented corrective actions.
Time management and organization to prioritize tasks and meet production schedules while maintaining workmanship standards.
Ability to work collaboratively in a team environment and to mentor less experienced technicians.
Adaptability to handle changing priorities, engineering updates and production schedule fluctuations.
Continuous improvement orientation: proactive in suggesting process improvements and participating in root cause analysis.
Manual dexterity and physical stamina for repetitive tasks, lifting small to medium parts, and working in confined assembly spaces.
Professionalism and adherence to company policies, regulatory requirements and customer confidentiality.

Education & Experience

Educational Background

Minimum Education:

High School Diploma or GED and documented hands-on sheet metal or aircraft assembly experience.

Preferred Education:

Associate degree, technical diploma, or certificate in Aircraft Maintenance Technology, Sheet Metal Technology, Manufacturing Technology or Vocational/Trade School completion.
FAA A&P certification or equivalent aerospace maintenance certification is a plus for roles involving repair and return-to-service.

Relevant Fields of Study:

Aerospace/Aviation Maintenance Technology
Sheet Metal Fabrication / Welding Technology
Manufacturing Engineering Technology
Industrial Maintenance / Machine Tool Technology
Mechanical Technology

Experience Requirements

Typical Experience Range:

2–5 years of sheet metal fabrication and aircraft assembly experience for mid-level positions; 0–2 years acceptable for entry-level with apprenticeship.

Preferred:

5+ years of direct aerospace sheet metal assembly experience, including exposure to jet aircraft structures, rivet installation, and working under FAA or OEM manufacturing standards.
Demonstrated record of performing structural repairs, first article builds, and supporting production quality audits.