The Senior Mechanical Assembly Technician is a highly skilled hands-on professional responsible for leading the assembly, integration, and verification of complex aerospace mechanical systems and structures. This role ensures precise build quality for flight and non-flight hardware, guides junior technicians, supports process improvements, and interfaces directly with engineering, quality, and manufacturing teams. The technician is expected to exercise independent judgment in high-reliability assembly environments involving critical aerospace components.
Key Responsibilities:
Lead or independently execute advanced mechanical assembly and system-level integration of aerospace hardware (e.g., actuators, structures, enclosures, propulsion components)
Interpret and apply detailed engineering drawings, 3D models, process documentation, and quality standards with expert precision
Perform critical assembly operations such as torquing, riveting, bonding, sealing, interference fitting, and tolerance stacking
Conduct fit-checks, alignment procedures, and dimensional verification using high-precision measurement tools
Guide mechanical interfaces with electrical, fluidic, and thermal systems in support of multidisciplinary integration
Mentor and train junior technicians in proper aerospace assembly techniques and documentation practices
Assist with planning assembly sequences, tooling setup, and fixture utilization for efficient workflow
Support root cause analysis for assembly-related nonconformances, document corrective actions, and implement improvements
Collaborate with engineers to resolve technical build issues and optimize manufacturability
Ensure strict compliance with AS9100, customer specifications, and safety protocols
Key Focus Areas:
Expert-level mechanical integration and flight hardware assembly
Interpretation and execution of complex assembly documentation
Technical leadership, mentoring, and quality compliance
Problem-solving and process refinement on the production floor
Qualifications & Skills:
Education:
High school diploma or GED (required)
Technical certification, trade school diploma, or associate degree in aerospace manufacturing or mechanical technology (preferred)
Experience:
8–15+ years of mechanical assembly experience in aerospace, space systems, defense, or high-reliability mechanical environments
Proven experience with aircraft, spacecraft, satellites, or propulsion hardware builds from start to finish
Technical Skills:
Mastery of mechanical assembly tools, processes, and documentation standards
Proficient in interpreting engineering drawings, GD&T, exploded views, and build procedures
Skilled with torque tools, height gauges, laser alignment tools, calipers, and micrometers
Familiarity with ERP/MES systems and digital work instruction platforms
Understanding of cleanroom protocol and FOD prevention in aerospace
Soft Skills:
Strong leadership and mentorship capabilities
Excellent communication skills and cross-functional collaboration
Proactive, quality-focused, and highly organized
Able to lead builds and troubleshoot issues under tight production deadlines