Composite Toolmaker

Act Aerospace•Gunnison, UT

About The Position

A Composite Toolmaker (Aerospace Composite Layup Tooling) builds, maintains, and continuously improves the molds, mandrels, fixtures, and ancillary tooling that make aerospace composite parts repeatable, inspectable, and certifiable at production scale. In modern aerospace manufacturing, toolmakers are not “support labor”—they are a primary determinant of dimensional accuracy, surface quality, cycle time, and first-pass yield because composite structures inherit both geometry and defect risk from their tooling, layup interfaces, and cure set-ups. The FAA’s composite airworthiness guidance emphasizes that composite structural reliability depends on repeatable manufacturing or repair processes, and on strong material and process control (specifications, acceptance testing, and process parameters representative of production). [1] In practice, this role fuses precision toolmaking (machining, assembly, metrology) with composites process proficiency (vacuum integrity, debulking, bagging stacks, cure tooling prep, material handling, and controlled documentation). Leading aerospace employers describe tooling roles as responsible for programming, fabrication, assembly, maintenance, inspection, and repair of tools, using a wide range of processes and equipment (machine tools, measurement equipment, and shop methods). [2] This report provides a professional, adaptable job posting plus research-backed responsibility mapping, qualifications, compensation benchmarks, and a hiring workflow (including a practical skills test checklist and interview structure). The goal is a posting that is specific enough to attract qualified aerospace composite-tooling talent, while remaining flexible across programs (defense, space, commercial aero, prototypes, or rate production). Role scope and responsibilities Role purpose and manufacturing context The Composite Toolmaker’s purpose is to ensure that composite layup tools and cure set-ups (molds, mandrels, trim fixtures, drill fixtures, bond fixtures, and handling frames) are built and maintained to print, remain vacuum tight and thermally stable, and are supported with controlled work instructions and inspection records. This aligns with FAA guidance noting that composite material behavior varies significantly with processing methods and that repeatable/controlled processes are central to producing reliable structure. [1] Core responsibilities and daily tasks for composite layup tooling The following responsibility set is written to match what aerospace employers actually post for toolmaking and composite-assembly roles, and then extends it with composite-layup-tooling specifics (vacuum bagging, autoclave prep, material control, and repair). [3] Tool fabrication and mold making The job commonly includes planning the build, interpreting models/prints, and then fabricating, assembling, inspecting, and repairing tools. [4] Typical daily tasks include: Interpreting engineering data: tool drawings, models, templates, tool manuals, sketches, and digital files; planning operation sequences and build approach. [5] Machining and fitting tooling details: setting up and operating lathes, milling machines, grinders (manual and/or CNC) to produce tool details and assemblies to tolerance, then fitting/assembling to blueprint requirements. [6] Building tooling components such as drill bars, edge bars, lifting/clamping details, and designing/building tooling aids or temporary assembly fixtures. [7] Applying GD&T and shop math correctly for tool stack-ups, interfaces, and datum schemes (a recurring theme in aerospace tool postings). [8] Conducting in-process and final conformance checks (calipers, micrometers, height gages, dial indicators; and where available, laser tracking/CMM). [9] CNC programming and CAM support for molds/fixtures Many toolmaker postings explicitly expect CNC set-up and programming proficiency (or close partnership with CAM programmers) for milling/turning operations and tool repair/rework. [10] Daily activities may include: Translating CAD into manufacturing steps: selecting cutters, planning datum pick-ups, generating or editing toolpaths, and verifying tool motion to prevent crashes and protect mold surfaces. (Lockheed toolmaker postings emphasize interpreting CAD data and CNC programming as a basic qualification.) [11] Supporting rework: updating machining plans to correct out-of-tolerance features, repair damage, or adjust interfaces, then verifying results with appropriate measurement tools. [12] Vacuum systems, vacuum bagging stacks, and autoclave/oven preparation for tools Composite tooling—especially high-performance molds/structures—often requires disciplined bagging and cure preparation. A representative aerospace tooling posting includes “plumb and vacuum systems” and verification via pressure testing/leak checking. [7] Tool-layup processing guides also emphasize preparation steps such as thermocouple placement, release film selection, breather laydown, bag slack management to avoid bridging, and pre-cure vacuum integrity checks. [13] Toolmaker-specific daily tasks include: Installing, maintaining, and troubleshooting tool vacuum plumbing (ports, seals, fittings), and verifying vacuum integrity through leak checks/pressure tests. [7] Building/assisting bagging stacks for tool cure or tool repair: selecting sealant tape, bag film, release films, breather/bleeder; ensuring proper slack and consolidation in corners to avoid bridging. [14] Supporting autoclave/oven readiness: thermocouple placement for temperature capture, verifying that bagging materials remain positioned as the bag pressurizes, and checking vacuum integrity prior to processing. [14] Maintaining cure-support documentation: traveler entries, vacuum logs, and equipment readiness checks where required by quality systems. (FAA composite guidance stresses controlled material/process specifications and traceable controls.) [15] Composite material handling for tooling and layup support Even for “tooling-first” roles, real postings frequently include composite layup activities (e.g., “lay-up” as a tooling fabrication process) or direct composite fabrication responsibilities. [16] For aerospace composite tooling, material handling is also a major quality lever: Managing prepreg out-time and storage: example industry guidance for tooling prepregs instructs keeping material frozen (e.g., -18°C / 0°F) to optimize out life, allowing material to reach room temperature before opening packaging to avoid condensation, and cutting on clean surfaces to prevent contamination. [17] Supporting kitting and ply preparation for tooling builds (templates, ply kits, staging plies to minimize freezer-out time). [17] Inspection, repair, and preventive maintenance of composite tools Toolmakers are repeatedly tasked with inspection and repair of tooling hardware and structures, including correcting out-of-tolerance tools and maintaining equipment. [18] In composite tooling environments, “repair” also includes: Surface and edge repairs: addressing dents, nicks, pinholes, resin-rich/lean spots, local delamination/disbond on a tool surface; restoring contour and surface finish to support part release and surface-quality requirements. (Composite maintenance guidance expects trained personnel and practical examination/qualification approaches.) [19] Dimensional restoration: building shims, inserts, or localized re-machining solutions; verifying alignment/clearances to specification using precision measurement and, where applicable, laser tracker/CMM workflows. [20] Preventive maintenance: cleaning, release-coating upkeep, vacuum seal maintenance, and basic equipment preventive maintenance as required by the shop. [21]

Requirements

Typically 3+ years in a manufacturing environment for a baseline toolmaking role (common supplier baseline).
For senior composite-tooling capability, many aerospace composite technician postings require ~7+ years of composite manufacturing (prepreg + bonding) and autoclave/cure vessel experience.
For traditional high-skill toolroom paths, postings may accept a Toolmaker certificate or ~10 years on-the-job training in a job shop tool fabrication environment.
Blueprint interpretation (including GD&T) and shop math; ability to build to tolerances and perform inspection for conformance.
Manual machining competence (mills, lathes, surface grinders) and safe operation of shop tools.
Composite tooling process familiarity: vacuum systems, leak checking, and/or vacuum-bag processing and cure support.
Documentation discipline and ability to work from written work instructions/process specifications (explicit in composite technician postings).
Common baseline: high school diploma/GED required, with trade school or college-level technical training preferred.
Many aerospace tooling postings require “U.S. Person”/export-control eligibility (ITAR/EAR) or U.S. citizenship depending on facility/program needs.
Ability to stand for long periods, bend/stoop, and perform repetitive hand work; ability to lift/handle tooling components with appropriate mechanical assist. (Toolmaker work activities often include physical handling and measurement tasks.)
Ability to wear PPE appropriate to composite operations and chemical handling; ability to pass respirator fit testing if required.

Nice To Haves

Familiarity with AS9100/EN9100 (9100 series) quality management systems, which add aviation/space/defense requirements beyond ISO 9001 and are widely used across the aerospace supply chain.
Awareness of (or experience supporting) NDI/NDT methods used for composite structures (tap test, ultrasonic A-scan/C-scan, etc.)—FAA composite maintenance technician training guidance explicitly includes NDT/NDI methods as part of foundational curriculum.
If the role interfaces directly with acceptance inspection or tool NDI, preferred certifications may include employer-based aerospace NDT certification aligned to NAS 410, widely described as a cornerstone aerospace standard for qualification/certification of NDT personnel.
ACMA Certified Composites Technician (CCT) is described by ACMA as an industry “gold standard” for composites manufacturing training, and the CCT handbook describes options including proctored exams and hands-on practical assessments.
(If the role supports certified repair station or MRO activities) familiarity with FAA composite technician training expectations is a plus; FAA AC 65-33A provides guidelines for training/qualification/certification programs for composite maintenance technicians.
NIMS credentials are a common way to document machining/CNC competency; NIMS describes its credentialing as industry-driven and widely recognized.
Some aerospace composite tooling environments require ability to obtain and maintain a U.S. Secret clearance or other program access; for example, a composite-tooling supplier toolmaker posting explicitly states the role may require ability to obtain U.S. Secret clearance and continuous evaluation.
Even if not required, including “ability to obtain and maintain clearance if program requires” can prevent avoidable late-stage disqualifications.
Some composite technician postings list “Aircraft & Powerplant license or similar professional certifications” as a desired qualification, especially where composite work intersects with aircraft systems or regulated maintenance environments.

Responsibilities

Interpreting engineering data: tool drawings, models, templates, tool manuals, sketches, and digital files; planning operation sequences and build approach.
Machining and fitting tooling details: setting up and operating lathes, milling machines, grinders (manual and/or CNC) to produce tool details and assemblies to tolerance, then fitting/assembling to blueprint requirements.
Building tooling components such as drill bars, edge bars, lifting/clamping details, and designing/building tooling aids or temporary assembly fixtures.
Applying GD&T and shop math correctly for tool stack-ups, interfaces, and datum schemes (a recurring theme in aerospace tool postings).
Conducting in-process and final conformance checks (calipers, micrometers, height gages, dial indicators; and where available, laser tracking/CMM).
Translating CAD into manufacturing steps: selecting cutters, planning datum pick-ups, generating or editing toolpaths, and verifying tool motion to prevent crashes and protect mold surfaces.
Supporting rework: updating machining plans to correct out-of-tolerance features, repair damage, or adjust interfaces, then verifying results with appropriate measurement tools.
Installing, maintaining, and troubleshooting tool vacuum plumbing (ports, seals, fittings), and verifying vacuum integrity through leak checks/pressure tests.
Building/assisting bagging stacks for tool cure or tool repair: selecting sealant tape, bag film, release films, breather/bleeder; ensuring proper slack and consolidation in corners to avoid bridging.
Supporting autoclave/oven readiness: thermocouple placement for temperature capture, verifying that bagging materials remain positioned as the bag pressurizes, and checking vacuum integrity prior to processing.
Maintaining cure-support documentation: traveler entries, vacuum logs, and equipment readiness checks where required by quality systems.
Managing prepreg out-time and storage: example industry guidance for tooling prepregs instructs keeping material frozen (e.g., -18°C / 0°F) to optimize out life, allowing material to reach room temperature before opening packaging to avoid condensation, and cutting on clean surfaces to prevent contamination.
Supporting kitting and ply preparation for tooling builds (templates, ply kits, staging plies to minimize freezer-out time).
Surface and edge repairs: addressing dents, nicks, pinholes, resin-rich/lean spots, local delamination/disbond on a tool surface; restoring contour and surface finish to support part release and surface-quality requirements.
Dimensional restoration: building shims, inserts, or localized re-machining solutions; verifying alignment/clearances to specification using precision measurement and, where applicable, laser tracker/CMM workflows.
Preventive maintenance: cleaning, release-coating upkeep, vacuum seal maintenance, and basic equipment preventive maintenance as required by the shop.