Aircraft maintenance is one of the most demanding and precision-driven disciplines in the engineering world. Whether it’s routine inspections, troubleshooting complex systems, or performing major overhauls, aircraft technicians rely on a wide array of tools — from highly specialised diagnostic instruments to precision-engineered general hand tools. Each tool plays a vital role in ensuring that aircraft remain safe, airworthy, and efficient.
In this article, in conjunction with the aviation tool experts at HSM Aviation, we’ll take a closer look at the types of tools you’d expect to find in an aircraft maintenance technician’s toolkit — covering both general-purpose equipment and aviation-specific instruments designed for the industry’s unique requirements.
- High-Quality General Tools
Even though aviation maintenance involves specialist procedures, every aircraft technician depends heavily on a foundation of premium general tools. The difference, however, lies in their precision, durability, and certification — as aviation standards demand equipment that meets exacting tolerances.
a) Hand Tools
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- Wrenches and Spanners: Aviation-grade open-end and combination wrenches, torque wrenches, and ratcheting spanners are essential for working on fasteners where precise torque is critical. Adjustable wrenches are often used, but only when properly calibrated.
- Screwdrivers: Sets of flathead, Phillips, and Pozidriv screwdrivers are common, often with insulated handles and magnetic tips for working in confined spaces. Aviation technicians often prefer hollow-ground screwdriver tips to prevent cam-out and damage to screw heads.
- Pliers and Cutters: Needle-nose pliers, safety wire pliers (for securing fasteners with locking wire), side cutters, and circlip pliers are all indispensable for manipulating wire and small components.
b) Measuring and Marking Tools
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- Calipers and Micrometers: Used for measuring wear on components and verifying tolerances to fractions of a millimetre.
- Steel Rules and Feeler Gauges: For checking clearances, gap settings, and alignment.
- Torque Wrenches: Critical for ensuring that fasteners are tightened to exact manufacturer specifications, preventing under- or over-tightening that could compromise safety.
c) Power Tools
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- Cordless Drills and Screwdrivers: Lightweight, low-torque cordless tools are often preferred to avoid overtightening and FOD (Foreign Object Debris) hazards.
- Pneumatic Tools: Air-driven drills and rivet guns are widely used in airframe work, particularly when working with aluminium skins and fasteners.
- Specialist Aircraft Maintenance Tools
Aircraft systems are far more complex than those found in automotive or industrial settings. As such, maintenance often requires specialist tools designed to meet the strict standards of aviation authorities such as EASA or the FAA.
a) Safety Wire Tools
Safety wire (lock wire) is a common method for securing fasteners against loosening due to vibration. Safety wire pliers and wire twisters are specialised tools that allow technicians to apply wire evenly and securely to critical components like engine bolts or control linkages.
b) Borescopes and Inspection Cameras
Aviation maintenance demands non-destructive inspection methods. Borescopes and video inspection cameras allow technicians to look inside engines, turbines, and airframes without disassembly. High-resolution optics and flexible probes make them invaluable for visual inspections.
c) Aircraft Jacks and Lifting Equipment
Aircraft are lifted for landing gear maintenance or wheel replacement using tripod jacks or axle jacks. These must be rated for specific aircraft weights and configurations, ensuring stability and safety during maintenance.
d) Torque Angle Gauges and Calibrators
Given the precision required, torque calibration tools are used regularly to ensure all torque wrenches and gauges are accurate and compliant with aviation standards.
e) Riveting and Sheet Metal Tools
A large part of aircraft structural maintenance involves working with aluminium and composite panels. Common tools include:
- Rivet guns and bucking bars
- Cleco fasteners for temporary alignment
- Deburring tools for removing sharp edges
- Dimpling and countersink tools for flush rivets
- Avionics and Electrical Testing Equipment
Modern aircraft are heavily reliant on electronic systems. Technicians working on avionics need access to a variety of diagnostic and measurement instruments.
- Multimeters and Oscilloscopes: For testing voltage, resistance, and signal integrity across complex avionics systems.
- Pitot-Static Testers: These simulate airspeed and altitude inputs to verify the accuracy of instruments like the altimeter and airspeed indicator.
- Bonding and Continuity Testers: Used to ensure proper electrical bonding of components to prevent static discharge or electrical interference.
- Battery Testers and Chargers: For maintaining aircraft battery health and ensuring readiness for emergency systems.
- Engine Maintenance Tools
Aircraft engines — whether piston or turbine — require specific instruments for inspection, alignment, and calibration.
- Compression Testers: Measure the health of piston engines.
- Fuel Pressure Gauges: Used to verify proper fuel flow and injection pressure.
- Vibration Analyzers and Balancers: Jet and propeller-driven engines require precise balance to prevent stress on mounts and bearings.
- Thermocouple and Temperature Probes: For monitoring engine temperature during testing and troubleshooting.
- Ground Support and Environmental Tools
Technicians also rely on larger pieces of ground equipment to support maintenance work:
- Tugs and Towbars for manoeuvring aircraft safely.
- Ground Power Units (GPUs) for supplying electrical power during servicing.
- Hydraulic Test Stands to simulate hydraulic system operation.
- Nitrogen and Oxygen Service Carts for pressurised systems and tyre servicing.
- Tool Control and Calibration
One of the defining features of aviation maintenance is tool accountability. Every tool must be logged in and out to prevent FOD incidents, and all measuring instruments must be periodically calibrated to certified standards. Many workshops now use digital tool control systems that track each item’s location and calibration status — an essential practice in maintaining airworthiness compliance.
Conclusion
An aircraft technician’s toolkit is a blend of craftsmanship and technology — from precision-engineered wrenches and micrometers to advanced digital testers and borescopes. Each tool plays a crucial role in maintaining the reliability, safety, and performance of modern aircraft.
While many of these tools might look similar to those used in other industries, their quality, precision, and calibration standards are far higher — because in aviation, even the smallest detail can make a world of difference.