Aerospace Structural Fabrication 2

Course Description

ETI2856C – Aerospace Structural Fabrication 2 is an advanced laboratory-intensive course in the Engineering Technologies taxonomy (Industrial Systems Technology) that builds upon the foundational skills established in Aerospace Structural Fabrication 1. Students advance their proficiency in metal and composite material fabrication, structural assembly, precision measurement, and quality inspection as applied to aerospace and aeronautics structures. The course integrates lecture content with extensive hands-on lab activities, requiring students to plan, fabricate, inspect, and document structural components and assemblies in accordance with industry drawings, specifications, and regulatory standards. Emphasis is placed on the higher-order fabrication skills—advanced riveting, structural repair, composite layup and repair, and assembly from engineering drawings—that prepare graduates for immediate entry-level employment in the aerospace manufacturing and maintenance sectors.

Learning Outcomes

Required Learning Outcomes

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

• Advanced Blueprint Interpretation: Read, interpret, and apply complex engineering drawings, geometric dimensioning and tolerancing (GD&T) symbols, and assembly specifications to plan and execute structural fabrication tasks.
• Precision Measurement and Inspection: Select and correctly use precision measuring instruments—micrometers, calipers, gauges, and optical comparators—to verify dimensional accuracy and conformance to aerospace tolerances.
• Advanced Rivet Installation and Removal: Demonstrate proficiency in the layout, drilling, countersinking, and installation of solid and blind rivets in aerospace sheet metal assemblies, as well as proper rivet removal techniques without structural damage.
• Sheet Metal Forming and Assembly: Apply advanced sheet metal forming techniques—bending, flanging, joggling, and trimming—to fabricate structural components that meet aerospace dimensional and surface finish requirements.
• Structural Fabrication Project: Plan, fabricate, inspect, and document a complete structural assembly from engineering drawings and written specifications, demonstrating integration of all course competencies.
• Quality Assurance and Documentation: Apply aerospace quality standards, perform in-process and final inspections, identify non-conformances, and complete required fabrication and maintenance documentation in accordance with industry and regulatory requirements.
• Aerospace Fasteners: Identify, select, and install a variety of aerospace fastener types—solid rivets, blind fasteners, bolts, screws, and special fasteners—to applicable specifications and torque requirements.
• Workplace Safety and Hazard Control: Identify hazards, apply OSHA and aerospace industry safety regulations, correctly use personal protective equipment (PPE), and handle hazardous materials in compliance with applicable standards.

Optional Learning Outcomes

Depending on institutional resources and program emphasis, students may also achieve the following:

• Composite Fabrication and Repair: Apply basic composite layup techniques using fiberglass, carbon fiber, and Kevlar materials; perform damage assessment; and execute structural composite repairs using wet layup or pre-preg methods in accordance with approved data.
• Adhesive Bonding: Select and apply structural adhesives for aerospace bonding applications, including surface preparation, adhesive application, cure processes, and bond-line inspection.
• Non-Destructive Inspection (NDI) Introduction: Demonstrate basic familiarity with visual, dye penetrant, and eddy current inspection methods used to detect surface and subsurface defects in aerospace structures.
• CNC and Automated Fabrication Awareness: Identify how CNC machining and automated drilling systems are integrated into modern aerospace structural fabrication workflows.
• Sealing and Corrosion Protection: Apply aerospace sealants and corrosion-inhibiting coatings to structural assemblies in accordance with engineering orders and material specifications.
• Electrical Bonding and Grounding: Understand and apply basic electrical bonding and grounding requirements associated with aerospace structural assemblies.

Major Topics

Required Topics

• Advanced Blueprint Reading and GD&T: Assembly drawings, detail drawings, tolerance stackups, surface finish symbols, and change documentation.
• Aerospace Materials – Advanced Applications: Properties of aluminum alloys, titanium, steel, and high-strength structural alloys; material identification, heat treatment effects, and material selection for structural applications.
• Aerospace Fasteners and Hardware: Classification and identification of solid rivets (AN/MS standards), blind fasteners (Huck, Cherry, NAS), structural bolts, hi-loks, lockbolts, and special-purpose fasteners; installation and inspection requirements.
• Precision Measuring and Testing Equipment: Selection, calibration, and use of micrometers, vernier and digital calipers, depth gauges, radius gauges, surface plates, and protractors to aerospace tolerances.
• Advanced Sheet Metal Fabrication: Setback and bend allowance calculations; flat pattern development; joggling, flanging, and dimpling; use of brakes, shears, and forming tools; edge and surface finishing.
• Rivet Layout, Drilling, and Installation: Rivet pattern layout; proper drill selection and technique; countersinking and dimpling; pneumatic and hand rivet gun operation; rivet inspection criteria (head formation, shop head, edge distance, spacing).
• Rivet Removal and Structural Repair: Rivet removal techniques without structural damage; damage classification and assessment; allowable damage limits; repair design from structural repair manuals (SRMs).
• Structural Assembly from Drawings: Planning and sequencing assembly operations; use of jigs, fixtures, and templates; drill-through and back-drilling techniques; shimming and fit-up.
• Aerospace Quality Standards and Documentation: AS9100/aerospace quality management principles; first article inspection; in-process and final inspection; non-conformance reporting; traveler and work order documentation.
• Workplace Safety – Advanced: Hazard identification; OSHA standards applicable to aerospace manufacturing; PPE selection and use; handling of cutting fluids, solvents, sealants, and other hazardous materials; emergency procedures.
• Capstone Structural Fabrication Project: Student-planned and executed fabrication of a multi-piece structural assembly from engineering drawings and specifications, incorporating measurement, assembly, fastening, inspection, and documentation.

Optional Topics

• Introduction to Composite Fabrication: Composite material history; fiber reinforcements (fiberglass, carbon/graphite, Kevlar); matrix systems; wet layup and pre-preg processes; curing methods; composite inspection.
• Composite Damage Assessment and Repair: Damage classification in solid and sandwich laminates; scarfing and stepping techniques; repair ply sequencing; adhesive application; post-repair inspection.
• Adhesive Bonding Techniques: Surface preparation (sanding, solvent wipe, chemical etch); adhesive types and selection; bonding processes; bond-line inspection methods.
• Introduction to Non-Destructive Inspection (NDI): Visual inspection; dye penetrant testing (PT); eddy current testing (ET) fundamentals; interpretation and documentation of findings.
• Sealing Applications: Sealant types, mixing ratios, and pot life; faying surface and fillet sealing; application tooling and cleanup; safety requirements for sealant use.
• Corrosion Identification and Prevention: Types of corrosion in aerospace structures; surface treatment and coating systems; corrosion removal and treatment procedures.
• Electrical Bonding and Grounding in Structures: Purpose and principles of bonding; bonding jumper installation; resistance measurement and acceptance criteria.

Resources & Tools

• Textbooks / Reference Manuals: Aviation Maintenance Technician Handbook – Airframe (FAA-H-8083-31), Vol. 1 (Sheet Metal and Composite Structures); applicable Structural Repair Manuals (SRMs); SpaceTEC CertTEC study materials for Aviation Structures Technician and Basic Composites.
• Hand and Power Tools: Pneumatic rivet guns and squeezers, hand drills, air-powered drill motors, countersink cages, bucking bars, rivet sets, hand seamers, sheet metal brakes and shears, deburring tools, safety wire pliers.
• Precision Measuring Instruments: Micrometers (outside, inside, depth), digital vernier calipers, radius gauges, surface plates, combination squares, protractors, rivet gauges.
• Fabrication Equipment: Sheet metal brakes, slip rolls, shears, drill press, band saw, bench grinders, surface grinding equipment, jigs and fixtures.
• Materials: Aluminum alloy sheet stock (2024-T3, 6061-T6), structural rivets (AN470, AN426), blind fasteners, structural adhesives, sealants, composite fabrics and resins (where applicable).
• Standards and Specifications: AN/MS/NAS fastener standards; ASTM material specifications; AS9100 quality management system references; applicable OSHA 29 CFR 1910/1926 regulations.
• Industry Certification Resources: SpaceTEC CertTEC Aviation Structures Technician exam preparation materials; SpaceTEC CertTEC Basic Composites preparation materials (optional track).

Career Pathways

Graduates of this course — typically within the Aerospace Technician CCC or Aerospace Technology A.S. degree pathway — are prepared for entry-level and advancing positions in Florida's robust aerospace, aeronautics, defense, and space industries, including organizations that support NASA, the Department of Defense, and commercial space companies.

• Aerospace Structural Fabricator / Sheet Metal Technician – Fabricates, forms, and assembles metallic airframe structures per engineering drawings and specifications.
• Structural Assembly Technician – Installs fasteners, performs drilling and riveting, and assembles structural subassemblies on aircraft or spacecraft.
• Aerospace Quality Control Inspector – Performs dimensional and visual inspection of fabricated structural components; documents non-conformances.
• Composite Fabrication Technician – Lays up and cures composite structural components; performs damage assessment and repair (with composite track).
• Aircraft Structural Repair Technician – Assesses and repairs structural damage to metallic and composite airframe components per approved maintenance data.
• Manufacturing Technician – Aerospace – Supports production operations in aerospace manufacturing facilities producing launch vehicles, satellites, and defense systems.

Credits earned in this course may apply toward the Aerospace Technology A.S. degree and the Structural Assembly Technician College Credit Certificate (CCC) at participating Florida colleges.

Special Information

Certification Preparation

This course prepares students to pursue industry-recognized credentials administered by SpaceTEC Partners, Inc. (National Science Foundation Center for Aerospace Technical Education), including:

• CertTEC Aviation Structures Technician (Level 1): A three-part exam (written, oral, and practical) assessing competencies in structures knowledge, fabrication methods, health and safety, inspection and repair, and regulations and documentation. Course content directly aligns with this credential's competency framework.
• CertTEC Basic Composites Technician (optional track): Covers composite history, fiber reinforcements, matrix systems, basic fabrication, inspection, damage assessment, and repair. Applicable when composite content is included.
• SpaceTEC Certified Aerospace Technician® (CAT) Core: An entry-level industry certification recognized across the aerospace sector. Students completing the full Aerospace Technology program sequence are eligible to sit for the Core exam, followed by concentration exams in Aerospace Manufacturing, Composites, or Structures and Assembly.

SpaceTEC certifications are FAA-recognized and accredited by the International Certification Accreditation Council (ICAC) to meet ISO 17024 guidelines, and are accepted by employers including NASA contractors, Department of Defense suppliers, and commercial aerospace manufacturers.

Program-Specific Notes

• This is a limited-access course typically offered as part of a structured cohort sequence. Students should consult with the program advisor regarding cohort scheduling (day or evening) and application deadlines.
• Students who hold a valid FAA Airframe and Powerplant (A&P) Certificate or a SpaceTEC Certified Aerospace Technician Certificate may be eligible for advanced standing credit at participating institutions.
• All laboratory sessions are conducted in-person; this course is not available in fully online or hybrid formats due to the hands-on fabrication requirements.