Senior Aircraft Fabricator

Calspan LLC•Niagara Falls, NY

4d•$28 - $38•Onsite

About The Position

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.

Requirements

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

Nice To Haves

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

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