Aircraft Sheet Metal Mechanic

Aircraft Structural Mechanic

We are seeking a highly skilled and detail-oriented Aircraft Structural Mechanic to support ongoing flight operations. This role encompasses full-cycle fabricationfrom raw material to finished, coated componentincluding precision metalworking, structural assembly, and aerospace-grade surface finishing. The ideal candidate combines strong manual structural skills with proven experience in corrosion control, priming, and top-coating of aluminum structures.

Responsibilities

Assemble, and install aircraft structural and mechanical components per engineering drawings, technical orders, and flight-test requirements

Perform precision sheet metal work: layout, cutting, forming, drilling, peening, and riveting

Create custom brackets, fittings, and mechanical hardware using manual machines (e.g., Bridgeport mill, analog lathe)

Conduct surface preparation and finishing in accordance with FAA and OEM standards, including:

Degreasing, abrading, and chemical etching of aluminum substrates, application of Alodine

Spraying or brushing epoxy primers and polyurethane topcoats

Support flight-test operations when required: rapid fabrication, modification, and in-situ finishing of test articles at field locations

Conduct self-inspections and coordinate with QA to verify structural integrity, coating quality, and dimensional accuracy

Maintain tools, fixtures, and 5S-compliant workspaces; adhere to safety, environmental, and security protocols

Qualifications

Minimum 35 years of verifiable experience in aircraft structures, structural repair, or related aviation manufacturing

Demonstrated proficiency with manual fabrication tools and equipment (e.g., rivet guns, brakes, shears, drill presses)

Strong ability to read, interpret, and work from analog technical documentation (blueprints, sketches, work cards)

Knowledge of aircraft metals, corrosion control principles, and basic composite repair

Hands-on experience with aircraft surface finishing processes, including Alodine application, epoxy priming, and polyurethane top-coating

Commitment to safety, documentation, regulatory compliance (FAA Part 43/91), and environmental standards

U.S. citizenship required, with the ability to obtain and maintain a U.S. security clearance

Willingness and flexibility to travel infrequently (up to ~20 days/year) to support flight testing

FAA Airframe Rating (A&P)

Military airframe training and/or experienceespecially those with structural/fabrication, corrosion control, or flight-test support roles

Hands-on experience with analog lathe operations (turning, facing, threading, tapering)

Proficiency with Bridgeport-type vertical milling machines for precision machining of brackets, fittings, and custom hardware

Prior work in MRO (Maintenance, Repair, and Overhaul)

Relocation assistance is available for eligible candidates.

Why join Calspan?

Be Calspan Culture

At Calspan, we promote an environment that empowers employees and encourages innovation. Our management team enables a strong sense of teamwork with each endeavor, where successes are shared and lessons are learned. The company's talent brand, "Be Calspan", incorporates our company values to Be Inclusive, Accountable, and Innovative and our commitment to drive every individual to - Be Developed, Be Balanced, Be Connected, Be Community and Be Recognized. Our culture promotes a positive atmosphere and competitive can-do method of action.

Great Benefits = Happy, Committed Employees

Retaining great talent is as important as finding it, so at Calspan, we take our employee value proposition of Be Calspan quite seriously. To us, that means offering competitive compensation, comprehensive benefits, recognition programs and promotional opportunities. Our benefits include: Health Insurance, Health Savings Accounts, Flexible Spending Accounts, Dental Insurance, Vision Insurance, Life Insurance/Accidental Death & Dismemberment, Short-Term/Long-Term Disability, 401(k), Hospital Coverage, Accident Coverage, Life Insurance Policy, Paid-Time Off, Company-paid Holidays, Bereavement Leave, Jury Duty, Military Leave, Employee Assistance Program, Educational Assistance Reimbursement, and Pet Insurance.

Calspan is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, or veteran status. Calspan supports safe and drug free workplace through pre-employment background checks and drug testing.

The salary range provided is a general guideline. Actual pay will depend on several factors, including, but not limited to, education, experience, training, and other applicable qualifications. Calspan is committed to pay transparency in compliance with applicable state and local laws.

All candidates must be eligible to work in the United States.

Salary Range (min)

USD $40.00/Hr.

Salary Range (max)

USD $60.00/Hr.