Aircraft Composite Repair Technician

Job Description

Job Description

Kaman Air Vehicles is seeking an Aircraft Composite Repair Technician at our Bloomfield, CT location to support the manufacturing, assembly, inspection, repair, restoration, and balancing of rotor blade components using adhesives and composite materials. This role requires strong mechanical aptitude, attention to detail, and the ability to follow written and verbal work instructions, engineering drawings/specifications, and OEM technical data to produce and return high-quality aerospace components to service in a safe, team-oriented environment.

About KAV: Kaman Air Vehicles is an industry leader in rotorcraft systems, unmanned aircraft solutions, and precision aerospace components. Our team supports customers across defense and commercial markets with proven platforms like the K-MAX and leading-edge autonomous technologies. We are driven by engineering excellence, mission readiness, and a culture that encourages innovation, teamwork, and pride in supporting critical aviation missions.

Essential Duties and Responsibilities

• Execute manufacturing and repair work to specification by accurately following work orders, travelers/routers, process sheets, and written/verbal instructions; ensure only current, controlled technical data is used.
• Manufacture and assemble rotor blade components using adhesive bonding and composite processes, including surface preparation and setup of structures for room-temperature or thermal cure across materials such as wood, composites, sheet metal, and machined parts.
• Escalate nonconformances to Engineering/Quality as required.
• Execute composite and bonded repairs in accordance with OEM instructions and FAA- acceptable/approved data, including masking, cleaning, abrasion/sanding, feather/scarf preparation, ply layup/lamination, core replacement/repair, adhesive bonding, vacuum bagging, and controlled curing.
• Perform metallic blade repairs where authorized (e.g., blending, surface restoration, corrosion treatment, minor structural repair per approved data) and restore blade surface condition and protective finishes/coatings as required.
• Remove discrepant material/boards from blades using woodworking hand tools and applicable mechanical equipment; shape and blend wood surfaces using templates and contour-matching techniques (by template or visual blending) to meet blade profile requirements.
• Perform blade weight and balance activities as required (e.g., static balancing, match sets, allowable weight adjustments) per OEM/approved instructions; use precision measuring equipment and calibrated tools to verify dimensional, surface, and weight requirements; conduct final inspection/verification steps prior to Quality acceptance and release.
• Safely operate hand and power tools (e.g., mallets, scissors, knives, rotary tools/dremels, sanders, drills) while maintaining good tool discipline and workmanship.
• Accurately document all work performed, including materials/lot traceability where required, and complete production and maintenance record entries per applicable requirements; follow controlled quality procedures (e.g., inspection checkpoints, tool control, shelf-life/out-time controls for resins/adhesives, FOD prevention).
• Support fixture and material handling needs, including assisting with moving fixtures as required.
• Maintain safety, environmental, and quality compliance while meeting production targets; comply with chemical handling, dust control (composite sanding), PPE, storage/handling, and waste disposal requirements; stop work and escalate unsafe conditions promptly.
• Contribute to continuous improvement by providing input to improve technical documentation, work instructions, and certification processes.
• Work effectively within a team by communicating clearly, maintaining a positive mindset, taking ownership of assigned work, and demonstrating consistent attention to detail; participating in training and skill development as provided/required for the role.

Required Qualifications

Education: High school diploma or GED equivalent.

Required Skills:

• Ability to read, have basic math skills and follow work instructions, drawings, specifications, and OEM technical data.

• Mechanical aptitude and proficiency with common shop tools and precision measurement equipment; strong attention to detail and workmanship standards.

• Working knowledge of composite manufacturing and repair processes (surface preparation, bonding, layup/lamination, vacuum bagging, curing, finishing) or ability to learn through provided training.

• Ability to complete documentation accurately and follow a controlled quality system; clear communication and teamwork skills.

Preferred Skills:

• 2+ years of manufacturing experience (composites or related field preferred) and/or experience in rotor blade repair, composite structural repair, aircraft component repair, or closely related aerospace manufacturing/repair work.

• Experience with composite repair and/or adhesive bonding is a plus.

• Experience working in an FAA-certificated Repair Station (Part 145) or equivalent controlled repair environment.

• Familiarity with calibration/tool control expectations for inspection equipment used for airworthiness determinations.

• Familiarity with material control requirements (traceability, shelf-life/out-time controls, freezer management).

Physical Requirements:

• Ability to stand/walk for extended periods; frequent bending, reaching, and fine motor work.

• Ability to lift and push up to 25 lbs., occasionally higher.

• Ability to wear required PPE (respirator, gloves, eye protection) and work around solvents/adhesives, sanding dust, and curing equipment.

• Ability to perform hands-on production work that requires standing, reaching, bending, and repetitive tool use in a manufacturing environment.

Work Environment and Safety

Work is performed in a production and repair setting where adherence to safety, environmental, and quality procedures is mandatory. Employees may work with adhesives, resins, solvents, sanding dust, curing equipment, and power tools and will be expected to follow PPE and safe handling practices. Maintain clean and organized work areas, ensure proper storage/handling of chemicals and composite materials, follow waste disposal requirements, and stop work for unsafe conditions.

Benefits:

At KAV, we recognize how important your career and benefits are to you and your family. We offer a full suite of benefits, including medical, dental, vision, short and long-term disability coverage, accident insurance, critical illness insurance, basic and supplemental life insurance, employee assistance plan, retirement savings and matching, and other developmental opportunities. We are committed to supporting the way you live and work.

KAV is an Equal Opportunity Employer. We consider all qualified applicants without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, veteran status, or any other legally protected status. Applicants requiring reasonable accommodation to complete the application process may contact Human Resources.

This position requires access to information subject to the International Traffic in Arms Regulations (ITAR). Employment is contingent upon the applicant being a “U.S. person” as defined by ITAR (22 CFR §120.15), which includes U.S. citizens, lawful permanent residents, refugees, or asylees, as required by U.S. export control laws.