Do you fabricate custom ductwork?

Yes. Everything is made by hand in our Novato shop, custom ducts, transitions, plenums, and fittings cut to your exact measurements.

What materials do you work with?

Galvanized steel, aluminum, stainless, and copper, for both HVAC ductwork and architectural pieces like flashing, hoods, and chimney caps.

Can you match an existing system?

Absolutely. Custom fabrication means we can match odd sizes and older systems that off-the-shelf parts won’t fit.

Do you do commercial sheet metal?

Yes, from light-commercial duct systems to rooftop unit transitions and make-up air, fabricated and installed to code.

4.8 (200+ reviews)

Custom Sheet Metal Fabrication & Ductwork in Marin County

Custom ductwork built to fit and last. Marin’s family sheet metal shop since 1960. In-house fabrication for ductwork, chimney caps, and architectural metal, built to last by one local crew.

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Air Conditioning Cool. Efficient. Reliable. Heating Warm. Comfortable. Safe. Sheet Metal Custom. Durable. Built Right.

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Licensed & InsuredCA Lic. #278370Fully bonded & insured

BBB AccreditedBetter Business BureauA+ Rating

NATE CertifiedNorth American Technician Excellence

Novato ChamberProud community chamber member

SMACNA MemberSheet Metal & AC Contractors’ National Assn.

Sheet Metal

Every sheet metal service we offer

AAERO HVAC restaurant cutaway showing ductwork

AAERO HVAC service van outside a Novato home with central air ducted vents and smart thermostat

The Aaero Difference

65 years of metal made by hand in Novato

No catalog parts, no guesswork, just custom sheet metal cut, bent, and seamed in our own downtown Novato shop by the same family-owned crew, fabricating for Marin since 1960.

AAERO HVAC technician diagnosing a home air conditioning system with a multimeter before quoting an upfront repair estimate

01, Our Own Fab Shop

A real fabrication shop, not a parts counter.

Aaero has run its own sheet metal shop in downtown Novato since 1960. Bring us a measurement or a drawing and we cut, brake, and seam the piece in house, so you get custom fabrication instead of whatever the catalog happens to stock.

Made on site in NovatoBrakes, shears, and seamers under one roof.
Odd sizes welcomeWe match older systems and tight runs.
One-off piecesIf it can be drawn, we can form it.

AAERO HVAC technician arriving to service an outdoor air conditioning condenser at a Marin County California home

02, Built To Your Spec

Every piece formed to your measurements.

We take the dimensions off the job and fabricate to them, whether that is a duct transition, a chimney top, or a skylight saddle. Custom sheet metal means the part fits the first time, with no shimming or filling to cover a near miss.

Cut and bent to sizeDuctwork, fittings, flashings, and hoods.
Copper, brass, stainless, aluminumThe right metal for the job and the setting.
Coastal-grade choicesCopper and brass for salt-air locations.

Family-owned Aaero technician reviewing an HVAC service estimate with a Marin County homeowner

03, Family-Owned Since 1960

Three generations at the same brakes.

The Milano family has fabricated metal in Novato since 1960, and the same hands that draw your job form it. Licensed (C20 and C43) and BBB accredited with an A+ rating since 1983.

Licensed #278370 (C20 · C43)HVAC and sheet metal under one roof.
A+ BBB since 1983Family-owned and accountable to Marin.
Marin, Sonoma & NapaAcross Marin, Sonoma, and Napa.

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Sheet metal in Marin County

Custom sheet metal fabrication, ductwork, and architectural copper for the North Bay

Aaero is one of the last family-owned HVAC contractors in Marin County with its own working sheet metal shop, and most days you can still hear brakes, shears, and snap-lock benches running behind our Novato office. We fabricate ductwork, plenums, flashings, gutters, downspouts, vent caps, and architectural panels in galvanized steel, aluminum, copper, brass, and stainless, all built to SMACNA standards and sized for the specific home or building they’re going into. Owning the shop means we can solve airflow problems, leaky roof penetrations, or one-off retrofit pieces in days instead of waiting weeks on an outside supplier.

Illustration of an AAERO HVAC van outside a Marin County building with custom rooftop ductwork and supply registers fabricated in our Novato shop

Custom sheet metal fabricated in our Novato shop

Stock duct fittings rarely fit the real-world joist bays, beam pockets, and chase walls of a Marin home, especially in older Mill Valley, Sausalito, and San Anselmo houses where nothing is square. Our journeyman fabricators cut, bend, and snap-lock custom plenums, transitions, returns, end caps, and offsets to the dimensions our installers measure on site, with no oversized boxes hidden in a closet to make a generic piece work. Every fitting is sealed with mastic or UL-181 tape, hung to SMACNA spec, and labeled so the next technician, even if it isn’t us, can read the system at a glance.

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Residential ductwork system designed and installed by Aaero in Marin County

Residential ductwork engineered for real Marin airflow

A new high-efficiency furnace or heat pump is only as good as the ducts behind it, and most homes we inspect have undersized returns, leaky plenums, and supply runs that can’t deliver the air a modern variable-speed system needs. We perform Manual D duct designs on every retrofit, replace flex-duct rats’ nests with hard-pipe trunk and branch in galvanized steel, and use Aeroseal or mastic to take leakage well below the California Title 24 threshold. The result is quieter operation, balanced room-to-room temperatures, and equipment that lasts longer because it’s no longer choked.

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Custom Sheet Metal Fabrication & Ductwork in Marin County

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Every sheet metal service we offer

65 years of metal made by hand in Novato

A real fabrication shop, not a parts counter.

Every piece formed to your measurements.

Three generations at the same brakes.

Custom sheet metal fabrication, ductwork, and architectural copper for the North Bay

Custom sheet metal fabricated in our Novato shop

Residential ductwork engineered for real Marin airflow

All Residential HVAC Services

AC Repair

AC Installation

Heating Repair

Heating Installation

Mini-Split Installation

Whole-House Zoning

Indoor Air Quality

Duct Cleaning

Maintenance Plans

Custom Sheet Metal