Fabrication Technician

Job Description

Job Description

JOB TITLE:  Fabrication Technician

DEPARTMENT: Operations Machine Shop

REPORTING TO: Team Lead of Aircraft Production & Maintenance

Founded in 1955, Piasecki Aircraft Corporation (PiAC) is a research and development business specializing in design, fabrication and flight testing of experimental rotorcraft and unmanned air vehicles. Piasecki has developed and flown more than 25 different advanced VTOL and UAV aircraft and continues to develop cutting-edge vertical flight technologies.

SUMMARY:

The Prototype Machinist & Aircraft Integration Mechanic at Piasecki Aircraft Corporation is responsible for bridging the gap between engineering concept and physical flight hardware. Working in our dedicated prototype machine shop, this role will manufacture high-precision, low-volume components using manual and NC equipment, and directly install and integrate those parts onto experimental aircraft. The mechanic will fabricate “one-off” components, execute structural and mechanical aircraft alterations, maintain rigorous AS9100 documentation, and collaborate directly with design engineers, purchasing, and flight test teams in an agile, fast-paced development environment.

RESPONSIBILITIES:

• Fabricates, assembles, and installs prototype equipment on rotorcraft for use in production and research/development
• Interpret blueprints, modification work orders, technical orders, and military technical manuals
• Install prototype equipment on aircraft and make modifications to the existing airframe to accommodate installations
• Coordinates with project engineer personnel throughout the project providing technical assistance to project engineers, contractors, ad factory representatives, etc.
• Set up and operate manual and numeric-controlled (NC) 3-axis milling machines, engine lathes, drill presses, saws, and basic sheet metal fabrication tools.
• Produce complex, tight-tolerance metallic and non-metallic prototype parts directly from engineering drawings, CAD models, sketches, or red line markups.
• Install prototype mechanical, structural, and electro-mechanical systems onto prototype and test aircraft.
• Execute structural modifications, retrofits, and airframe alterations in accordance with engineering disposition, design change notices (DCNs), and flight test requirements.
• Perform precision drilling, reaming, fastener installation, and fit checks directly on the airframe.
• Perform first-article dimensional inspections using precision measurement tools and maintain AS9100 traceability for all raw materials, hardware, and tools.
• Follow internal work instructions, complete traveler/router logbooks, and generate non-conformance reports (NCRs).
• Partner directly with design and stress engineers to evaluate design-for-manufacturability (DFM) and design-for-assembly (DFA).
• Coordinate with the purchasing department to outsource certain production steps, e.g. surface treatment and identify tooling, raw stock, and specialized hardware.
• Performs sheet metal repairs to a variety of rotorcraft, possess an in-depth knowledge of sheet metal materials and repair techniques
• Works with various thickness of aluminum, steel alloys, stainless steel, copper, brass and other ferrous and non-ferrous metals in the fabrication of production metal parts for aircraft modifications
• Operates tools and equipment associated with sheet metal shop operation such as protractors, calipers, gauges, crimping tools/machines, forming machines, lathes, milling machines, saws, drilling presses, gas and heli-arc welding machine
• Understand and interprets blueprints , schematics and rudimentary drawings
• The Fabrication Technician may be required to perform other related duties to meet the ongoing needs of the organization

KNOWLEDGE / SKILLS / ABILITIES:

• Demonstrated competency running manual 3-axis mills, lathes, and/or NC controlled machines without supervision.
• Proficient in reading and interpreting aerospace engineering blueprints, revision blocks, and Geometric Dimensioning and Tolerancing (GD&T) per ASME Y14.5.
• Practical familiarity working under AS9100, ISO 9001, or equivalent regulated aerospace quality management systems
• Working experience with aerospace alloys (aluminum 2024/7075, stainless steels, titanium, 4130 chromoly) and engineering plastics.
• Basic CAD/CAM experience (e.g., Fusion 360, Mastercam, or SolidWorks) for conversational NC toolpath generation.
• Strong problem-solving, analytical, and teamwork skills with the ability to mentor shop technicians.
• Sheet metal forming and composite structure fabrication experience is required and TIG welding desired.
• Computer skills specifically using Microsoft Office Suite; ability to learn additional computer skills or software programs. Working knowledge of advanced software applications is preferred
• Ability to understand and interpret documents such as safety rules, operating and maintenance instructions, and procedure manuals.
• Strong professional customer service skills, including active listening, prompt service and follow-up.
• Strong decision analysis and problem-solving skills; ability to draw conclusions and justify decisions. Must be able to communicate issues to management.
• Ability to learn and understand corporate policies and procedures and how they relate to goals.
• Ability to perform basic mathematical computations
• High degree of self-motivation and the ability to work independently
• Capable of lifting up to 25 lbs. overhead, on feet all day, walk up to 2 miles per day.

EDUCATION / CERTIFICATIONS / CLEARANCES:

• Minimum 3 years of hands-on experience in precision machining, toolmaking, or prototype aircraft fabrication/assembly.
• Certified Machinist (Journeyman, vocational trade certification, or recognized trade apprenticeship) or aviation maintenance experience equivalent with documented machining proficiency) required.
• Prior experience working on experimental or prototype aircraft in a R&D, startup, or flight-test environment preferred.