Aircraft Manufacturing and Maintenance Engineering Syllabus

The syllabus differs according to whether the programme is a diploma, B.Sc, B.Voc, B.Tech, integrated course or licensing pathway. The following curriculum is representative and should not be interpreted as the official syllabus of every institution.

First-Year Subjects

Engineering Mathematics: Algebra, calculus, differential equations, vectors, matrices, probability and numerical methods used in engineering analysis.

Engineering Physics: Mechanics, waves, optics, material properties, electricity, magnetism and physical principles relevant to flight and instrumentation.

Engineering Chemistry: Corrosion, fuels, lubricants, polymers, composites, surface treatment and engineering materials.

Engineering Mechanics: Forces, moments, equilibrium, friction, centroids, motion and basic structural analysis.

Engineering Drawing and Graphics: Orthographic projection, sectional views, dimensioning, tolerances and interpretation of technical drawings.

Basic Electrical Engineering: Direct and alternating current, circuits, machines, transformers, batteries and electrical safety.

Basic Electronics: Semiconductor devices, diodes, transistors, amplifiers, digital logic and electronic measurement.

Computer Programming: Programming fundamentals, problem-solving and introductory computational applications.

Workshop Practice: Fitting, machining, welding, sheet-metal work, measurement, fasteners and safe use of tools.

Communication Skills: Technical writing, presentation, teamwork, workplace communication and report preparation.

Second-Year Subjects

Fluid Mechanics: Fluid properties, pressure, continuity, momentum, flow measurement, boundary layers and compressible-flow introduction.

Thermodynamics: Properties of gases, laws of thermodynamics, cycles, heat transfer and energy conversion.

Strength of Materials: Stress, strain, bending, torsion, columns, deflection and failure principles.

Aircraft Materials: Aluminium alloys, steels, titanium, composites, ceramics, elastomers and material-selection considerations.

Manufacturing Processes: Casting, forming, machining, welding, joining, surface treatment and process planning.

Metrology and Measurement: Limits, fits, tolerances, gauges, measuring instruments, calibration and dimensional inspection.

Basic Aerodynamics: Airflow, lift, drag, aerofoils, stability introduction and aircraft performance fundamentals.

Aircraft Structures: Fuselage, wings, empennage, control surfaces, structural loads and construction methods.

Aircraft Systems: Hydraulic, pneumatic, fuel, landing gear, flight-control, environmental and fire-protection systems.

Electrical and Electronic Fundamentals: Aircraft electrical generation, distribution, wiring, circuit protection and electronic systems.

Computer-Aided Design: Two-dimensional drafting, three-dimensional modelling, assemblies and engineering documentation.

Third-Year Subjects

Aircraft Production Technology: Production planning, tooling, jigs, fixtures, assembly sequencing and aircraft manufacturing organisation.

Composite Manufacturing: Lay-up techniques, curing, bonding, sandwich construction, defects, inspection and repair principles.

Aircraft Propulsion: Piston engines, gas turbines, compressors, combustion chambers, turbines, propellers and engine performance.

Avionics: Communication, navigation, instruments, displays, sensors, data buses and automatic flight-control fundamentals.

Maintenance Practices: Workshop safety, tools, torque procedures, locking devices, pipes, hoses, cables, bearings and maintenance documentation.

Non-Destructive Testing: Visual, dye-penetrant, magnetic-particle, ultrasonic, eddy-current and radiographic inspection principles.

Quality Control and Assurance: Inspection planning, process control, traceability, audits, non-conformity management and corrective action.

Reliability and Maintainability: Failure behaviour, reliability measures, preventive maintenance, condition monitoring and maintainability analysis.

Aviation Legislation: Regulatory structure, airworthiness concepts, approved data, maintenance responsibilities and record-keeping.

Aircraft Inspection and Repair: Damage assessment, corrosion control, structural inspection and approved repair procedures.

Industrial Engineering: Work study, facility layout, production scheduling, inventory, productivity and lean-manufacturing concepts.

Final-Year Subjects

Aircraft Assembly and Integration: Major-component assembly, alignment, systems installation, rigging, functional checks and production testing.

Maintenance Planning and Management: Maintenance programmes, checks, resource planning, material control, task scheduling and aircraft downtime.

Airworthiness and Safety Management: Continuing airworthiness, human factors, occurrence reporting, risk management and safety culture.

Aircraft Troubleshooting: Systematic fault isolation, use of manuals, test equipment, defect analysis and verification after corrective action.

Computer-Aided Manufacturing: CNC concepts, process simulation, digital manufacturing and production-data management.

Advanced Manufacturing: Automation, additive manufacturing, robotics, smart tooling and digital inspection.

Human Factors in Aviation: Communication, fatigue, stress, situational awareness, teamwork, error management and organisational factors.

Economics and Project Management: Costing, budgeting, project planning, resource allocation and engineering decision-making.

Internship or On-the-Job Training: Supervised exposure to manufacturing, maintenance, quality or technical operations.

Major Project: A design, manufacturing, maintenance, reliability, inspection or systems-related project supported by analysis and documentation.

Representative Semester-Wise Syllabus

Common Elective Subjects

Electives may include:

• unmanned aerial vehicle technology;
• helicopter systems;
• airline engineering management;
• advanced composite structures;
• computational fluid dynamics;
• finite-element analysis;
• additive manufacturing;
• aviation safety;
• supply-chain management;
• aircraft accident investigation;
• condition-based maintenance;
• structural health monitoring;
• aircraft interiors;
• sustainable aviation;
• industrial automation;
• aviation cyber security;
• digital twins; and
• maintenance, repair and overhaul management.

Practical Training

Practical training is central to the course. Students may practise:

• identification and safe use of hand tools;
• precision measurement;
• drilling, riveting and sheet-metal work;
• cable and control-system inspection;
• removal and installation of components;
• wiring inspection and electrical testing;
• corrosion identification and treatment;
• composite inspection and repair;
• engine familiarisation;
• use of maintenance manuals;
• preparation of job cards and technical records;
• defect reporting;
• dimensional inspection;
• non-destructive testing demonstrations;
• CAD modelling;
• CNC programming; and
• quality-documentation procedures.

The presence of practical subjects in a brochure does not prove that adequate equipment or training time is available. Students should inspect laboratories and workshops, ask how many learners share each setup and confirm whether practical tasks are individually assessed.

Project Ideas

Final-year projects may cover:

• composite aircraft panel manufacturing;
• corrosion-detection systems;
• predictive aircraft maintenance;
• drone airframe design and fabrication;
• aircraft component traceability;
• digital maintenance records;
• tool-control systems;
• landing-gear condition monitoring;
• engine-vibration analysis;
• automated visual inspection;
• lightweight structural optimisation;
• additive manufacturing of non-critical components;
• maintenance scheduling;
• human-factor risk analysis;
• aircraft cabin-material testing; and
• quality improvement in an aerospace production line.

Projects involving operational aircraft or safety-critical components must be conducted under competent supervision and applicable safety procedures.