Senior Aircraft Fabricator

Overview

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

Responsibilities

• Fabricate, 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
• Fabricate 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

Required Qualifications:

• Minimum 3–5 years of verifiable experience in aircraft fabrication, 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

Preferred Qualifications

• FAA Airframe Rating (A&P)
• Military airframe training and/or experience —especially 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) or production fabrication environments

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. 

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