Key Responsibilities and Required Skills for Jet Sheet Metal Fabricator

🎯 Role Definition

The Jet Sheet Metal Fabricator is responsible for producing high-quality aerospace sheet metal parts and assemblies to engineering specifications. This role combines hands-on metal forming, cutting, and joining with detailed inspection and documentation. The ideal candidate reads complex blueprints and prints, sets up and operates CNC and manual fabrication equipment (press brakes, shears, turret punches, laser cutters), performs riveting and secondary assembly, and adheres to strict aerospace quality and safety standards (FAA, NADCAP). This position supports production schedules, continuous improvement initiatives, and cross-functional teamwork to deliver on-time, on-spec components for jet aircraft structures and interior hardware.

📈 Career Progression

Typical Career Path

Entry Point From:

Sheet Metal Apprentice or Trainee
CNC Operator / Machine Setter
Aircraft Assembly Technician

Advancement To:

Senior Sheet Metal Fabricator / Journeyman
Lead Fabricator or Production Lead
Fabrication Supervisor or Manufacturing Manager

Lateral Moves:

Quality Inspector (Aerospace)
Tooling & Fixtures Technician
Aircraft Structural Repair Technician

Core Responsibilities

Primary Functions

Interpret and accurately apply engineering drawings, blueprints, and technical specifications (including GD&T) to fabricate aircraft skins, ribs, brackets, and complex formed components within specified tolerances.
Set up, program (where applicable), and operate press brakes, including tooling selection, bend sequence development, and spring-back calculation to produce precision bends for thin-gauge and thicker aerospace alloys.
Operate CNC turret punch presses, laser cutting machines, waterjet, and shear equipment to cut and form sheet metal parts to exact dimensions while monitoring for consistent part quality.
Perform hand-forming, stretch forming, shrink forming, and rotary draw bending for complex contours and compound shapes used in fuselage and wing components.
Lay out and mark materials using precision measuring tools, transfer dimensions from prints to raw stock, and perform accurate hole location and pattern layout for fasteners and rivets.
Install and set structural rivets (solid rivets, flush rivets) and nutplates using pneumatic rivet guns, bucking bars, and pullers, ensuring correct countersink depths and flush finishes.
Perform countersinking, dimpling, and reaming operations to prepare assemblies for flush fasteners and to prevent cracking and fretting during service.
Conduct fit-up and assembly of multi-piece structures, aligning joints, shimming as required, and performing trial assemblies to verify form and function before final riveting or fastening.
Use handheld and bench tools (drills, drills presses, deburrers, grinders, files) to finish parts, remove burrs, and prepare mating surfaces to specified surface finishes and edge breaks.
Read and implement material specifications for aluminum alloys, stainless steels, titanium, and specialty aerospace materials, including handling, storage, and destruction protocols where applicable.
Perform dimensional inspection of parts using calipers, micrometers, height gauges, optical comparators, and CMM data collection when required to verify conformity with drawing tolerances.
Document fabrication steps, complete traveler paperwork, inspection records, and electronic work orders in the company’s ERP or MES system to maintain traceability and part history.
Follow aerospace quality systems and regulatory requirements (FAA, NADCAP, AS9100) including first article inspections (FAI), nonconformance reporting (NCR), and corrective action documentation.
Troubleshoot fabrication issues and perform root cause analysis on fit-up problems, dimensional drift, tooling wear, and machine setup errors; propose and implement corrective actions.
Maintain and perform preventive maintenance on fabrication equipment, tooling, and gauges to ensure continuous, safe operation and to minimize downtime.
Apply basic welding techniques (MIG/TIG/stitch weld) where required for assembly or repair work, and perform pre- and post-weld finish processes in line with quality standards and certifications.
Execute repair and modification work on in-service components and structural assemblies, following approved engineering changes, SRM procedures, and repair manuals.
Ensure compliance with shop safety standards, PPE usage, material handling protocols, and hazardous material handling policies; participate in safety audits and toolbox talks.
Collaborate with engineers, quality inspectors, and production planners to support design-for-manufacture feedback, tolerance improvements, and cost-reduction initiatives.
Train and mentor junior fabricators and apprentices on shop best practices, blueprint reading, tool usage, and quality expectations to build bench strength in the fabrication team.
Prioritize workload to meet production schedules, coordinate with inventory and procurement on material availability, and escalate supply or tooling constraints that impact delivery timelines.
Perform finishing operations such as anodizing preparation, masking, protective coating application, and part packaging to preserve part integrity during shipping and storage.

Secondary Functions

Support first article inspections (FAI) and special process validations by preparing samples, gathering evidence, and assisting Quality with verification activities.
Contribute to continuous improvement projects (5S, Kaizen, job cycle reduction) by documenting waste, suggesting fixture improvements, and piloting process changes.
Assist engineering with prototype development, rapid iteration, and small-batch manufacturability assessments for new jet component designs.
Participate in cross-functional problem-solving sessions related to material yield, tolerance stack-up, and manufacturing throughput bottlenecks.
Maintain fabrication tooling inventory, recommend replacement cycles, and support tooling design with sketches or feedback for jigs and fixtures.
Help prepare training materials and SOPs for new fabrication processes and equipment, ensuring knowledge retention across shifts and teams.
Support ad-hoc quality investigations by recreating part failures or performing bench-level troubleshooting to identify manufacturing-related root causes.
Collaborate with supply chain and lead times teams to advise on alternative material choices or subcontract operations when in-house capacity is constrained.

Required Skills & Competencies

Hard Skills (Technical)

Advanced blueprint and engineering drawing interpretation, including geometric dimensioning and tolerancing (GD&T) and aerospace symbols.
Proficient use of press brakes (manual and CNC), including crowning, back gauges, and tooling selection to achieve tight-bend tolerances.
Experience operating CNC turret punches, laser cutters, waterjet systems, and shears for precision sheet cutting.
Riveting and fastener installation expertise: solid rivets, flush rivets, blind rivets, nutplates, rivet guns, and pullers.
Proficiency with measurement and inspection instruments: digital calipers, micrometers, height gauges, bore gauges, and optical comparators.
Familiarity with ERP/MES systems and electronic traveler documentation for part traceability and production reporting.
Working knowledge of aerospace materials (aluminum alloys, titanium, stainless steel) and heat-treatment or corrosion-protection considerations.
Basic welding skills (MIG/TIG) and experience with welding prep and grinding for assembly where applicable.
Experience with countersinking, dimpling, reaming, drilling jigs, and ream-to-size processes to meet flush-mount fastener requirements.
Ability to perform first article inspections (FAI) and ensure compliance with AS9100, FAA, or NADCAP quality requirements.
CNC programming fundamentals or strong machine setup skills to translate CAM output and tooling data into accurate setups.
Competence in interpreting technical change notices (TCNs), engineering change orders (ECOs), and implementing revised work instructions.

Soft Skills

Meticulous attention to detail and commitment to producing defect-free, airworthy components.
Strong problem-solving and troubleshooting skills with a methodical approach to root cause analysis.
Effective communication skills to interact with engineers, quality inspectors, and production planners.
Time management and organization to prioritize work on busy production floors and meet tight delivery schedules.
Team player mentality with the ability to train, mentor, and support multi-shift teams.
Safety-first mindset, promoting workplace safety and adherence to PPE and lockout/tagout procedures.
Adaptability and willingness to learn new fabrication technologies and processes.
Continuous improvement orientation—comfortable identifying inefficiencies and proposing practical solutions.
Dependability and accountability in documenting work, logging inspections, and maintaining traceability.

Education & Experience

Educational Background

Minimum Education:

High School Diploma or GED; strong emphasis on mechanical aptitude and hands-on experience.

Preferred Education:

Technical certificate or associate degree in Sheet Metal Technology, Manufacturing Technology, Welding, or Aerospace Fabrication.
Completion of a recognized sheet metal apprenticeship program or FAA-recognized training.

Relevant Fields of Study:

Sheet Metal Technology / Fabrication
Aerospace Manufacturing Technology
Welding Technology / Mechanical Technology
Industrial Maintenance / CNC Machining

Experience Requirements

Typical Experience Range: 2–7 years of hands-on sheet metal fabrication experience; 3+ years preferred for aerospace-specific roles.

Preferred: Proven track record in aerospace or aviation manufacturing environments, familiarity with FAA/NADCAP/AS9100 standards, experience with first article inspections (FAI), and demonstrated competency with both manual and CNC fabrication equipment.