Aerospace Structural Fabrication 1

Course Description

ETI1855C – Aerospace Structural Fabrication 1 is a 3-credit, hands-on laboratory course within the Engineering Technologies > Industrial Systems Technology taxonomy of the Florida Statewide Course Numbering System (SCNS). The course introduces students to the foundational principles and practical skills of aerospace structural fabrication, including the safe use of hand and power tools, blueprint reading, precision measurement, sheet metal layout and forming, and fastening techniques such as riveting. Students apply these skills through structured shop projects that simulate real aerospace manufacturing and assembly environments. The course prepares students for entry-level positions in metal fabrication and structural assembly in the aerospace, aeronautics, space launch, and defense sectors.

This course is commonly offered as part of the Structural Assembly Technician Certificate and the Aerospace Technician College Credit Certificate (CCC) at Florida colleges such as Eastern Florida State College (EFSC). Instruction combines classroom lectures with extensive hands-on laboratory activity.

Learning Outcomes

Required Outcomes

Upon successful completion of this course, students will be able to:

• Identify and safely operate hand tools, bench tools, and power tools used in aerospace structural fabrication.
• Apply shop safety procedures, including the correct use of personal protective equipment (PPE) and compliance with OSHA standards for industrial environments.
• Read and interpret aerospace blueprints, engineering drawings, and technical specifications to guide fabrication tasks.
• Perform accurate layout and measurement using precision measuring instruments such as calipers, micrometers, and gauges.
• Execute sheet metal layout, bending, and forming operations, including calculating bend allowances and preparing parts from flat stock.
• Identify and install conventional and special rivets and aerospace fasteners to applicable standards and specifications.
• Demonstrate proper drilling techniques, including hole layout, drilling precise holes, deburring, countersinking, and dimpling.
• Apply aerospace industry terminology and acronyms relevant to structural components, hardware, and fabrication processes.
• Complete a hands-on structural fabrication project from drawings and specifications, demonstrating mechanical skills and adherence to quality standards.

Optional Outcomes

The following outcomes may be covered depending on program sequence and institutional emphasis:

• Identify physical properties, metallurgy, and temper designations of aerospace-grade aluminum alloys and other structural metals.
• Describe major structural stresses (tension, compression, shear, torsion, bending) as they apply to aircraft structural members.
• Perform basic sheet metal repair operations, including inspection of damage and selection of appropriate repair methods.
• Apply geometric dimensioning and tolerancing (GD&T) concepts when interpreting fabrication drawings.
• Recognize corrosion types, prevention methods, and surface treatment processes relevant to aerospace metals.
• Demonstrate awareness of composite and honeycomb structural materials used in aerospace applications as an introduction to advanced coursework.

Major Topics

Required Topics

• Shop Safety and OSHA Standards – Personal protective equipment (PPE), hazard identification, safe tool operation, and workplace safety regulations.
• Aerospace Industry Orientation – Industry terms, acronyms, structural nomenclature, and overview of aerospace manufacturing roles and environments.
• Hand Tools and Power Tools – Selection, proper use, and maintenance of tools standard to aerospace structural fabrication shops.
• Precision Measurement – Use of calipers, micrometers, rules, gauges, and measuring systems; applying tolerances to fabricated parts.
• Blueprint Reading and Technical Drawings – Interpreting orthographic views, assembly drawings, detail drawings, title blocks, notes, and revision levels.
• Mathematics for Metal Fabrication – Applied math including fractions, decimals, geometry, and calculations for layout, bend allowance, and setback.
• Sheet Metal Layout and Bending – Flat pattern layout, bend lines, bend allowance calculations, use of brake presses and hand brakes to form sheet metal parts.
• Drilling Operations – Hole layout, drill selection, drilling to precise diameter, deburring, countersinking, and dimpling procedures.
• Rivet Identification and Installation – Types of conventional and special rivets, rivet nomenclature, selection criteria, rivet layout, spacing and edge distance requirements, and installation using rivet guns and bucking bars.
• Fasteners and Hardware – Aerospace-grade bolts, screws, nuts, washers, and special fasteners; installation and removal procedures.
• Hands-On Fabrication Projects – Structured shop projects including lap splice assemblies, channel fabrication, and panel assemblies built to blueprints and technical specifications.

Optional Topics

• Aerospace Materials and Metallurgy – Physical properties of aluminum alloys, temper designations, stainless steel, titanium; heat treatment concepts and non-metallic materials overview.
• Structural Stress Concepts – Tension, compression, shear, torsion, and bending loads in fuselage, wing, and flight control structures.
• Hand Forming Techniques – Joggle forming, rolling, shrinking, stretching, and forming compound curves by hand.
• Corrosion Identification and Prevention – Types of corrosion affecting aerospace metals, inspection methods, cleaning procedures, and surface treatments.
• Sheet Metal Repair Fundamentals – Damage assessment, repair classification, use of the Structural Repair Manual (SRM) and AC 43.13-1B, and basic repair fabrication.
• Geometric Dimensioning and Tolerancing (GD&T) – Introduction to GD&T symbols and their application to aerospace fabrication drawings.
• Introduction to Composite Materials – Overview of composite and honeycomb sandwich structures used in aerospace, as preparation for advanced fabrication coursework.
• Quality Assurance Concepts – Inspection methods, workmanship standards, and documentation practices relevant to aerospace fabrication.

Resources & Tools

• Textbooks / References: FAA Airframe & Powerplant Mechanics Airframe Handbook (FAA-H-8083-31); AC 43.13-1B, Acceptable Methods, Techniques, and Practices – Aircraft Inspection and Repair; manufacturer Structural Repair Manuals (SRMs).
• Shop Equipment: Sheet metal hand brakes, slip rolls, English wheels, rivet guns, bucking bars, drill presses, pneumatic drills, deburring tools, layout dye and scribers.
• Measurement Instruments: Vernier calipers, micrometer sets, combination squares, protractors, and thickness gauges.
• Reference Standards: Aerospace Material Specifications (AMS), Military Specifications (Mil-Spec), and OSHA 29 CFR 1910 General Industry Safety Standards.
• Software / Digital Tools: Basic CAD drawing viewers for blueprint interpretation (optional, instructor-dependent).

Career Pathways

Completion of ETI1855C supports entry into and advancement within the following career areas:

• Aerospace Structural Fabricator / Sheet Metal Mechanic – Fabricating and assembling structural components for space launch vehicles, aircraft, and ground support equipment.
• Aerospace Structural Assembly Technician – Assembling structural subassemblies from blueprints for aerospace OEMs and contractors.
• Aircraft Sheet Metal Mechanic – Performing sheet metal repair and fabrication at MRO (Maintenance, Repair & Overhaul) facilities and repair stations.
• Composite Fabricator – Entry pathway; advanced composite skills developed in subsequent coursework (e.g., ETI1856C or equivalent).
• Quality Control / Inspection Technician – Inspecting fabricated structural parts and assemblies for conformance to drawings and specifications.

Florida employers hiring graduates include organizations supporting NASA Kennedy Space Center, the Department of Defense, commercial space companies (SpaceX, Blue Origin, United Launch Alliance), and major aerospace corporations operating on Florida's Space Coast and beyond. Credits earned in this course may apply toward the Structural Assembly Technician Certificate, the Aerospace Technician College Credit Certificate (CCC), and the Aerospace Technology A.S. degree.

Special Information

Certification Preparation: This course provides foundational skill preparation aligned with national aerospace technician certification competencies. Students who complete the full Aerospace Technician CCC sequence at participating Florida colleges (such as EFSC) are prepared to sit for industry certification examinations as Aerospace Technicians in structural skill areas, as recognized by the Florida Department of Education and industry partners.

Program Admission: At many Florida colleges, ETI1855C is part of a limited-access, cohort-based program. Students must complete a separate program application in addition to general college admissions. Prospective students should contact the program advisor at their institution for specific admission requirements, cohort start dates, and prerequisite verification.

Industry Alignment: Course content is aligned with competencies recognized by the National Center for Aerospace and Transportation Technologies (NCATT) and supports pathways toward FAA Airframe and Powerplant (A&P) certification for students who continue into aviation maintenance programs.