Reports to: Sheet Metal Lead

Job purpose

The Sheet Metal Technician is responsible for inspecting, fabricating, modifying, repairing, and installing sheet metal structures on rotary-wing aircraft in accordance with manufacturer specifications, engineering drawings, and aviation regulatory standards. This role is critical in ensuring airframe integrity, safety, and optimal performance.

Duties and Responsibilities

• Inspect and assess damage to sheet metal structures on helicopters.
• Read and interpret blueprints, technical drawings, engineering orders, and OEM manuals.
• Fabricate replacement parts and assemblies using metal forming techniques and equipment.
• Remove, repair, and reinstall aircraft skin panels, stringers, bulkheads, and other structural components.
• Perform drilling, riveting, bending, cutting, filing, deburring, and sealing tasks.
• Use precision tools and measurement devices to ensure accuracy and fit.
• Complete repairs in accordance with FAA regulations, OEM specs, and internal procedures.
• Document all repairs and modifications in maintenance logs and work orders.
• Work closely with engineering, maintenance, and inspection teams for signoffs and quality control.

Workplace Safety:

• Adhere to OSHA, FAA, and company-specific safety guidelines at all times.
• Utilize proper PPE including gloves, safety glasses, hearing protection, and respiratory protection when required.
• Operate tools and equipment in accordance with safety protocols.
• Maintain clean, organized, and hazard-free areas.
• Report any safety concerns, accidents, or near misses immediately

SOP/KPIs:

• Follow all SOPs for structural repair, fabrication, and assembly tasks.
• Ensure all work complies with company and regulatory standards.
• Meet or exceed KPIs including:
  • Work order completion rate
  • Quality assurance pass rate
  • Rework frequency
  • Safety compliance metrics

Team Support:

• Collaborate effectively with maintenance technicians, engineers, and inspectors.
• Support project teams during helicopter refurbishment, modification, or heavy maintenance visits.
• Assist and mentor junior technicians or apprentices when needed.
• Communicate progress and potential issues clearly with supervisors and team leads.
• Maintain best practices and a positive working environment with all parties at the worksite.
• Coordinate with other departments to achieve outlined goals.
• Respond to communications (e-mails, meeting requests, Teams messages, etc.) set by team members in a timely and friendly manner.
• Learn SmartSheets project management software and take ownership of assigned projects.  Aid in the evolution of usage of this platform by spearheading best practices adoption.

Qualifications:

• Experience: 3+ years of experience in aircraft sheet metal work, preferably on helicopters or rotary-wing aircraft.
• Certifications: Completion of an FAA-approved Airframe and Powerplant (A&P) school or equivalent training preferred.
• Legal: Must be authorized to work in the U.S.

Required Behaviors:

• High attention to detail with a strong commitment to precision and quality.
• Professional, dependable, and safety conscious.
• Strong work ethic and willingness to adapt to changing priorities.
• Accountability and pride in workmanship.

Hard Skills & Education:

• Education: High school diploma or GED required, A&P License preferred.

Technical Skills:

• Skilled in using hand tools, power tools, and specialized aviation sheet metal equipment.
• Proficient in riveting, countersinking, drilling, dimpling, and forming sheet metal.
• Ability to read and interpret complex technical documents and engineering instructions.
• Understanding of aircraft structures and material types including aluminum alloys and composite interfaces.

Specific Soft Skills (examples):

• Effective communication skills and teamwork mentality.
• Strong problem-solving and critical thinking abilities.
• Ability to manage time efficiently and work under tight deadlines.
• Commitment to continuous learning and improvement

Working conditions

• Indoor hangar environment with occasional outdoor work depending on project needs.
• Exposure to noise, vibration, sharp tools, and metal particles—PPE required.
• May be required to work overtime, weekends, or night shifts as project demands dictate.
• Must pass drug screening, background checks, and regulatory compliance requirements

Essential Job Functions

• Structural inspection, repair, and modification of helicopter sheet metal components.
• Reading and applying information from blueprints, drawings, and technical manuals.
• Operating sheet metal tools and equipment.
• Recording work performed for regulatory and internal documentation.
• Ensuring airworthiness and structural integrity of aircraft components

Physical requirements

• Ability to lift and carry up to 50 lbs.
• Frequent standing, climbing, bending, kneeling, and working in confined or elevated spaces.
• Good manual dexterity, vision, and hand-eye coordination.
• Capable of wearing safety gear for extended periods