Key Responsibilities and Required Skills for Jet Sheet Metal Worker

🎯 Role Definition

A Jet Sheet Metal Worker performs precision fabrication, repair, and assembly of aircraft and jet engine sheet metal components. This role requires reading complex blueprints and specifications, applying metal forming and fastening techniques to aerospace tolerances, and ensuring compliance with safety, quality, and regulatory standards (FAA, AS9100, NADCAP). The Jet Sheet Metal Worker contributes to maintenance, modification, and production activities across repair stations and manufacturing lines and partners with engineers, inspectors, and production planners to deliver airworthy structural components on schedule.

📈 Career Progression

Typical Career Path

Entry Point From:

Sheet Metal Apprentice program or trade school graduate (aerospace emphasis)
Aircraft Maintenance Technician (AMT) with sheet metal crossover experience
General sheet metal worker in industrial or HVAC environments transitioning to aerospace

Advancement To:

Senior/Lead Jet Sheet Metal Technician
Aircraft Structural Repair Lead or Repair Station Supervisor
Fabrication Team Leader or Production Planner
Quality Inspector (NDT/FAA) or Manufacturing Engineer (with further education)

Lateral Moves:

NDT Technician (ultrasonic, dye penetrant, eddy current)
Tooling & Fixture Technician
CNC/Press Brake Operator (advanced forming roles)

Core Responsibilities

Primary Functions

Read, interpret and apply complex aerospace blueprints, engineering drawings, and manufacturing work orders (including GD&T, hole charts, rivet schedules and material callouts) to fabricate or repair jet aircraft structural components to required tolerances.
Layout, measure and scribe sheet metal patterns using precision instruments (micrometers, calipers, height gauges, protractors) and establish datum points to ensure accurate part geometry before cutting or forming.
Cut and shape aluminum, titanium, stainless steel and other aerospace alloys using hand tools and powered equipment—nibbler, shear, band saw, laser, waterjet and press brake—while adhering to material grain, bend allowances and stress-relief requirements.
Form and bend sheet metal components on press brakes, rollers and manual dies using correct tooling, bend radius calculations and spring-back compensation to meet engineering specifications.
Perform hole preparation, countersinking, dimpling and flaring for flush and protruding fasteners; install and set solid rivets, blind rivets, Hi-Lok/Chris-Craft/bolts, and nut plates using pneumatic riveters, bucking bars and torque wrenches to specified torque values.
Execute structural repairs including patching, splice repairs, doublers, and replacement of skin and stringers following repair instructions (SRMs) and OEM repair procedures to restore structural integrity.
Pre-fit, assemble and tack components using clecos and temporary fasteners to verify fitment prior to final fastening and riveting sequences.
Perform edge preparation, deburring, scuffing, and surface finishing operations to meet aerodynamic and corrosion-control requirements; prepare surfaces for chemical treatments and coatings such as conversion coating, primer or paint.
Follow and document structural bonding processes, adhesive application and cure schedules when required by engineering drawings, including safe handling of adhesives and adherence to recommended environmental conditions.
Conduct first article inspections, in-process and final dimensional checks using hand tools, templates, go/no-go gauges and coordinate measuring machines (CMM) as applicable; record inspection data and ensure parts meet acceptance criteria.
Identify non-conforming parts and discrepancies, generate clear non-conformance reports (NCRs), provide containment actions and support root cause investigations with corrective action implementation.
Collaborate with engineering and design teams to provide manufacturability feedback, suggest design improvements, and prepare fabrication methods and tooling recommendations to reduce rework and increase producibility.
Interpret and apply regulatory and quality system requirements (FAA 145, AS9100, NADCAP) including traceability, documentation control, and process audit support to maintain repair station and manufacturing compliance.
Maintain accurate production and inspection records, material traceability, serial number documentation, and parts genealogy in line with quality system and customer requirements.
Execute safe rigging, lifting and fixturing of assemblies and structural subcomponents; secure heavy parts for forming, welding or finishing while following proper lifting charts and PPE protocols.
Apply and verify corrosion control practices, including surface treatments, anodizing preparation, and chemical handling in accordance with MSDS and company procedures to ensure long-term airworthiness.
Support NDT (dye penetrant, eddy current, ultrasonic) technicians by preparing and holding parts for inspection, documenting pre-inspection conditions and making permissible repairs following approved drawings.
Participate in job planning and production sequencing by estimating labor hours, tooling requirements and material needs; communicate schedule impacts and escalation when encountering engineering or material issues.
Mentor and train apprentices and junior technicians on fabrication techniques, shop safety, blueprint reading and quality expectations to raise team capability and consistency.
Maintain and calibrate hand tooling, gauges and shop equipment; report defective tools and take part in tooling selection and improvement initiatives to maintain capability and reduce downtime.
Follow LOTO (Lockout/Tagout), hazardous materials handling, and fire safety procedures; ensure work area cleanliness and adherence to housekeeping standards that support safety and regulatory compliance.
Assist in the preparation and support of customer and regulatory audits by providing process demonstration, documentation packages and traceability records for fabricated assemblies.
Participate in continuous improvement and Lean manufacturing activities—value stream mapping, 5S, Kaizen events—to optimize workflow, minimize waste, and improve on-time delivery of structural components.
Read and apply engineering change orders (ECOs), service bulletins and revision updates; implement drawing changes on the shop floor and revise work instructions as necessary to maintain configuration control.

Secondary Functions

Support ad-hoc fabrication requests and quick-turn repairs for AOG (Aircraft on Ground) events, prioritizing safety and speed while maintaining structural integrity.
Maintain and update material and tooling inventory levels; coordinate with procurement to ensure availability of aerospace-grade sheet stock, fasteners, and special tooling.
Assist quality and engineering in statistical process control (SPC) data collection and trending to identify recurring dimensional or process issues.
Contribute to the development and revision of standard work instructions, process flows and job aids that capture best practices and reduce variability between operators.
Help prepare job travelers, packing lists and shipping documentation for finished assemblies destined for MRO facilities or OEM integration.
Participate in training and cross-training programs to broaden shop capability across riveting, NDT support, forming and final assembly.
Provide input to safety committees and participate in workplace hazard assessments to improve personal and team safety.
Support digital tooling and nesting software operators by providing feedback on layout efficiency and material utilization for blanking operations.
Assist in the creation and maintenance of tooling drawings, jigs and fixtures used to hold assemblies during fabrication and fastening.
Participate in weekly production and quality stand-ups, communicating status, risks and mitigation plans to production leads and customers.

Required Skills & Competencies

Hard Skills (Technical)

Aerospace blueprint interpretation (GD&T, drill charts, rivet schedules, BOMs).
Precision measuring and layout (micrometers, vernier calipers, height gauges, protractors).
Metal forming and bending (press brake operation, roll forming, spring-back compensation).
Cutting and shearing (CNC shear, laser/waterjet/plate saw setup and operation).
Fastening and joining (solid rivets, blind rivets, Hi-Lok/Hi-Shear, nut plate installation, torque control).
Surface prep and finishing (deburring, countersinking, dimpling, edge forming).
Structural repair techniques to SRM/OEM instructions and repair station procedures.
Non-Destructive Test (NDT) awareness and support: dye-penetrant, eddy current, ultrasonic basics.
Familiarity with FAA regulations, AS9100 and NADCAP auditing elements and traceability requirements.
Use of inspection equipment (CMM, height gauge plates, bore gauges, go/no-go fixtures).
Adhesive bonding prep and cure control for structural adhesives (where applicable).
Experience with shop software and MES systems for production tracking and job documentation.
Basic welding and brazing familiarity for fit/repair (where allowed by processes and certifications).

Soft Skills

High attention to detail and precision mindset required for aerospace tolerances.
Strong problem-solving skills and mechanical aptitude in troubleshooting fit and finish issues.
Clear verbal and written communication for reporting NCRs, change notices, and shift handovers.
Teamwork and collaboration with engineers, quality, and production planners.
Time management and ability to prioritize AOG or high-priority repairs under deadline pressure.
Adaptability to changing work orders, engineering changes, and production priorities.
Initiative and willingness to mentor apprentices and share procedural knowledge.
Safety-oriented attitude with commitment to PPE, LOTO and shop safety standards.
Continuous improvement mindset and openness to process changes to increase efficiency.
Customer-focused professionalism when interacting with internal stakeholders and external auditors.

Education & Experience

Educational Background

Minimum Education:

High school diploma or GED with relevant trade experience.

Preferred Education:

Certificate or diploma from an accredited trade school, community college or apprenticeship program in sheet metal fabrication, aviation maintenance or aerospace manufacturing.
Associate degree in Manufacturing Technology, Aviation Maintenance Technology, or related technical field considered a plus.

Relevant Fields of Study:

Sheet Metal Fabrication / Metalworking
Aircraft Maintenance / Aviation Technology
Welding Technology / Manufacturing Technology
Mechanical or Industrial Engineering Technology

Experience Requirements

Typical Experience Range: 2–7 years of hands-on sheet metal fabrication in aerospace, MRO, or aircraft manufacturing environments.

Preferred:

5+ years of direct aerospace/jet sheet metal experience with documented work on aircraft skins, flight controls, nacelles or engine components.
Experience in a Part 145 repair station or production environment with AS9100/NADCAP exposure.
Certifications such as FAA Repairman/Mechanic endorsements, AWS (welding) or NDT Level I/II are advantageous.
Demonstrated proficiency with first article inspections, drawing revisions, and change implementation on the shop floor.