HYBRID- SHEETMETAL-COMPOSITE REPAIR TECHNICIAN

Introduction to become a HYBRID- SHEET METAL AND COMPOSITES REPAIR

FAA AC 65-33          Development of Training/Qualification Programs for Composite Maintenance Technicians

FAA AC 43-214        Repairs and Alterations to Composite and Bonded Aircraft Structure

This COURSE  contains the ATA104 level IV curricula.

General Composite Structural Bonded Repair Curriculum

Persons who successfully complete this basic training program are considered to be able to perform bonded composite repairs to composite structures in compliance with the manufacturer’s repair documentation or other acceptable repair data.
This curriculum should be considered a prerequisite for more advanced training.

Join our HYBRID course for AICRAFT SHEET METAL Technicians /workers/ Shop leads / Engineers learning to add COMPOSITE REPAIR to their Knowledge and Skills

Commercial aircraft structures are evolving rapidly. Composite materials now represent a significant portion of the structural surface area across fleets, already 55%.
Yet workforce structures inside many MROs have not evolved at the same pace.
Composite repairs are often concentrated in a small specialist group, while sheet metal technicians remain limited to metallic structures.
This separation creates operational bottlenecks.

The capability distribution problem

When composite workload increases:

  • Planning becomes reactive

  • Outsourcing increases

  • AOG exposure rises

  • Specialist overload develops

The issue is not technician competence.  It is a capability distribution.

Why Excisting Aircraft sheet metal technicians are the solution

Experienced sheet metal technicians already understand:

  • Structural load paths

  • Machining discipline

  • Repair documentation compliance

  • Fastener systems

  • Drilling and reaming in materials (Composites) 

Composite bonded repair adds new process control disciplines - not an entirely new professional identity.

With structured certification, sheet metal technicians transition efficiently into hybrid roles.

The sheetmetal hybrid workforce model for EASA / FAA-approved SAE- AIR4938 curricula

Part 1 – General Composite Structural Bonded Repair Certification (10 days / 76 hours)
Part 2 – Commercial Aviation Composite and Bonded Rtructure repair (10 days / 76 hours)
Part 3 – Optional (Drilling and Reaming in Advanced Composites (5 days / 40 hours)
Part 4 -  Commercial Aircraft Structure Metalbond Repair Curriculum (5 days / 40 hours)

The result:

Hybrid structural teams capable of executing metallic and composite repairs without operational segregation.

The financial argument to run this PART 1 course

  • Training is a predictable cost.
  • Downtime is an uncontrolled cost.
  • When composite repairs are distributed across the workforce, operational resilience increases

Conclusion

  • The future of structural maintenance is not metal or composite.
  • It is a HYBRID
  • MROs that redesign their workforce architecture will OUTPERFORM those that rely on specialist concentration.

    ATTACHED: PDF "Why A HYBRID  LEARNING ADDITIONAL COMPETENCY REPAIR FOR SHEET METAL WORKERS/TECHNICIANS"" SHOP LEAD AND MANAGEMENT COURSE ENROLMENT MOTIVATION 

Day(-s): 10 Days-76 hours / Tech code: TECH-130

AIRCRAFT SHEET METAL  with no Composite Repair knowledge

AIRCRAFT TECHNICIANS. Currently, with no knowledge of Composite Repair and skills who want to become a HYBRID technician combining Sheetmetal and Composite repair.

Our TECH-130 HYBRID uses the Composite curriculum  Part 1 General Composite training course as an advised prerequisite for the advanced PART 2 training, as the EFC--TECH-102 -Part 2 Commercial Aircraft Composite Structure Bonded Repair course.
Participant success will be in part based on their  knowledge and skills possessed before course enrollment:

  • Basic Technical Mathematics
  • Reading comprehension in Technical English 
  • Speaks and understands Technical English 

The follow-up for this course is the EFC-TECH-102 PART, which meets EASA-FAA & OEM SRM standards.


Aircraft SHEET METAL WORKERS who want to become a dual-skilled HYBRID-METAL - COMPOSITE REPAIR TECHNICIAN  and learn Commercial Aviation Composite Repairs.
Aircraft SHEETMETAL SHOP LEAD/Supervisors
Aircraft MEHANICS  -Technicians who want to learn the basics Comercial Aviation Composite Repairs


Minimum required 4 and maximum 8 per course*.

* Courses will be confirmed as running by EFC as soon as sufficient applications are received!

SHEET METAL WORKERS who successfully complete this (BASIC)  training program are considered to be able to perform bonded composite repairs to composite structures in compliance with the manufacturer’s repair documentation, like BOEING  or AIRBUS, and other types of aircraft parts, or other acceptable repair data.

This curriculum should be considered a prerequisite for more advanced training, EFC TECH-102- SAE-AIR4938 PART 2 EASA /FAA  Approved curriculum 

Teaching levels

The following definitions of minimum teaching levels are derived from Title 14 Code of Federal Regulations, Part 147, and may be exceeded.

Level 1
Level 1 requires knowledge of general principles and includes instruction through lectures, demonstrations, and discussions, but does not include practical application or the development of manipulative skills.
This teaching level generally refers to classroom discussion and does not require practical application.
Teaching aids or instructional equipment may include charts, books, diagrams, or other visual teaching aids. If a training organization chooses to teach Level 1 courses that incorporate actual components, those components do not have to be operational.

Level 2
Level 2 requires knowledge of general principles and includes instruction by lecture, demonstration, discussion, and limited practical application, but does not include development of sufficient manipulative skill to perform basic operations.
This teaching level requires some hands-on manipulative skills and their accompanying actual or simulated components/equipment, but still may be taught primarily in the classroom environment.

Level 3
Level 3 requires knowledge of general principles and includes instruction by lecture, demonstration, discussion, and a high degree of practical application to develop sufficient manipulative skill to accomplish return to service (normal operation).
This teaching level requires hands-on skills, as well as sufficient and appropriate instructional aids, to train students to develop manipulative skills sufficient to simulate return-to-service mechanical skills.
At this level, the teaching aids must be similar to or be the actual items of equipment on which the student is expected to develop required skill levels.
A Level 3 subject cannot be taught solely through lectures; appropriate training aids and hands-on experience must be used.

 

In this  TECH-130-HBRYD SHEET METAL- OMPOSITE REPAIR  course, we teach the following content, which is EASA / FAA-SAE-AIR4938 approved curriculum courses: 

  • EFC-TECH-101 EASA / FAA SAE AIR4938 PART 1  General Composite Structural Bonded Repair Curriculum  (10 days / 76 hours)
    See the course content. Click this link:   https://www.efcomposites.com/course/?id=tech-101

    As a follow-up, you can attend our PART 2
  • EFC-TECH 102 EASA / FAA Approved SAE-AIR4938 PART 2 Commercial Aircraft Composite Structure Bonded Repair Curriculum  (10 days / 76 hours)
    See its Course content doc./ Factsheet. Click this link: https://www.efcomposites.com/course/?id=tech-102

    As a follow-up, you can attend our PART 3
  • EFC- TECH 103-SAE-AIR 4938 Commercial Aircraft Composite Structure Bolted Repair Curriculum (5 day/40 hours)

    As a follow-up, you can attend our PART 4
  • EFC-TECH 104 SAE-AIR 4938 PART 4  Commercial Aircraft Structure Metalbond Repair Curriculum (5 days/ 40 hours)
    See its Course content doc./ Factsheet. Click this link: https://www.efcomposites.com/course/?id=tech-104

SEE  FACT sheet or Click this link:  https://www.efcomposites.com/course/?id=tech-101

SEE  FACT sheet or Click this link: https://www.efcomposites.com/course/?id=tech-102

Examination

  • Training Providers will be required to monitor student performance throughout the program.
  • Particiapant will be administered a written certification exam following lecture classes by the certifying agency.
  • Students will be administered a practical certification assessment following laboratory classes. It is recommended to use a checklist to evaluate the practical certification assessment.
  • The written certification examination and practical certification assessment will cover the principles of the applicable curriculum and consist of:

The written examination for certification shall contain approximately eight (8) multiple-choice questions per course day, with a maximum of forty-eight (48) / fifty (50)* per exam.
The examination shall include questions on each Topic listed in the outline for each Part. The examination will be closed-book.

* The number depends on the use of three or four alternative answers per question

Practical certification assessment: The student must demonstrate to the approved training provider that they can perform the basic tasks required to perform the applicable repairs.

Reexamination: If the student fails the written examination, they may request to retake it. The written examination must not contain more than 20% of the questions that were on the failed examination.

Certification

Part 1 certification shall l consist of documentation of successful completion of:

  • A repair training program, the required exams and assessments based on the curriculum of this SAE-AIR4938, and conducted by a training provider in accordance with the guidance set forth in this course
  • OR successful completion of the required exams and assessments based on the curriculum of the SAE- AIR4938 without completion of a training program.
    Attempting the exam and assessment without training is not recommended for personnel without composite repair experience.

Part 2, Part 3, and Part 4 certification shall consist of successful completion of A repair training program, the required exams and assessments based on the curriculum of this AIR, and conducted by a training provider in accordance with the guidance set forth in this AIR.

This course can also be held at our facility in Leipzig Germany at the facilities of our partner HEICO. If you have a need for this, please contact our purchasing manager Rolf Hovener via his page. For your company to benefit, this course can be held 'On-Site' at your facility under certain conditions.
Click on this link to the Onsite information webpage!

Courses as noted on our course schedule page can be run on request to meet your required start and end date. All listed course prices are Excl VAT. (Dutch VAT is 21%). EFC complies with Dutch tax laws. On request, companies can be sent an invoice instead of paying direct On-line with PayPal, IDEAL or credit card.

Payment is securely arranged via Mollie.nl . More information can be found on the website of Mollie.




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