Definition
A hand-held striking tool with a soft-faced head, made of wood, rubber, plastic, rawhide, or soft metal such as brass or lead, used to deliver blows to a workpiece without marring or deforming its surface.
Plain English
A hammer with a soft head. It hits things hard enough to move or seat them, but not so hard that it dents or scratches the surface.
Context Anchor
Seen in aircraft maintenance, especially when parts need to be fitted, loosened, or adjusted without using a hard steel hammer.
Derivation
From the Old French maillet, meaning 'small hammer,' itself from Latin malleus, 'hammer.' The soft-faced version kept the name but traded a hard steel head for materials that protect the work.
Why Pilots Care
Prevents accidental damage to thin skins, fairings, and components during fitting or adjustment.
Intuition Check
Do not think of a mallet as just any hammer. In aircraft work, the point is usually that it strikes more gently than a steel hammer.
Example Sentence 1
The mechanic used a rubber mallet to seat the wheel half against the bearing without scarring the aluminum.
Example Sentence 2
Reach for the mallet instead of a steel hammer when seating a fairing on aluminum.