The Senior Air Ducting Assembly Technician is responsible for the expert-level fabrication, installation, inspection, and repair of ventilation ducting systems for aircraft Environmental Control Systems (ECS). This role ensures that all duct assemblies meet engineering specifications, airworthiness requirements, and production quality standards. The technician leads hands-on operations on the shop floor or aircraft, mentors junior staff, and collaborates with quality, manufacturing engineering, and planning teams to support continuous improvement and regulatory compliance.
Perform advanced-level assembly and installation of rigid and flexible air ducts, insulation blankets, couplings, and support brackets on aircraft or in production environments
Read and interpret complex engineering drawings, blueprints, and build-to-print work instructions
Lead troubleshooting, fit-checks, rework, and modifications of duct systems to resolve non-conformances or integration issues
Use precision tools to trim, bead, flare, or swage duct tubing made of aluminum, titanium, or composite materials
Apply sealing compounds, protective coatings, and thermal insulation materials in accordance with aerospace standards
Ensure assemblies meet specifications related to airflow, sealing, vibration, and thermal insulation performance
Operate testing equipment for leak checks, pressure tests, and fit verifications
Document work performed in accordance with production and regulatory documentation standards (e.g., AS9100, FAA Part 145)
Collaborate with planning, engineering, and quality teams to resolve technical issues and implement corrective actions
Train and mentor junior and mid-level technicians in best practices, safety protocols, and workmanship standards
Support audits, first article inspections (FAI), and production readiness reviews as a technical subject matter expert
Advanced duct assembly and system integration
Interpretation of aerospace manufacturing and MRO documentation
Quality assurance and rework resolution
Mentorship and process improvement leadership
Education:
High school diploma or GED (required)
Technical diploma or training in aerospace manufacturing, sheet metal, or aircraft systems (preferred)
Experience:
5–8+ years of experience in air duct assembly or aircraft ECS installation in an OEM or MRO environment
Hands-on experience with metallic and composite ducting, aerospace hardware, and sealants
Experience working under FAA, EASA, or AS9100 quality systems
Familiarity with lean manufacturing or continuous improvement initiatives is a plus
Technical Skills:
Proficient in use of hand tools, power tools, tube bending/flaring tools, torque equipment, and calipers/micrometers
Strong understanding of airflow routing, vibration isolation, sealing practices, and ventilation design concepts
Ability to follow manufacturing planning, technical drawings, and aerospace specifications
Competent in using digital production systems (MES, SAP, or similar) and completing documentation accurately
Soft Skills:
High attention to detail and precision craftsmanship
Proven ability to mentor and train junior technicians
Strong communication and teamwork skills
Proactive approach to safety, quality, and productivity