Senior Reverse Engineer for Aerospace CAD & Prototyping

Zel Technologies LLC; Town of Florida (NY); Hybrid; USD 120,000 - 190,000; Full time

Job summary

Zel Technologies seeks an experienced Senior Reverse Engineering Specialist to support evaluation, analysis, redesign, and validation of complex mechanical components. Remote and onsite work may be required depending on project scope.

The ideal candidate has 12+ years of related experience, a mechanical/aerospace engineering background, and hands‑on expertise in reverse engineering, GD&T, and DFM for manufacturability and cost reduction.

Qualifications

• 12+ years related experience.
• Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Aerospace Engineering, or equivalent.
• Strong experience in reverse engineering mechanical systems and precision components.
• Experience with additive manufacturing technologies including FDM, SLA, SLS, metal printing, or hybrid manufacturing workflows.

Responsibilities

• Perform reverse engineering of mechanical components and assemblies using measurements, scans, CAD reconstruction, and physical inspection techniques.
• Analyze existing parts and generate manufacturable CAD models, engineering drawings, and technical documentation.
• Evaluate dimensional accuracy, tolerances, materials, finishes, and functional performance of components.
• Develop and improve designs for manufacturability, cost reduction, reliability, and repeatability.
• Support prototype development through additive manufacturing, machining, and fabrication processes.
• Conduct quality inspections and root‑cause analysis related to part failures, deviations, and production issues.
• Create inspection plans, validation procedures, and acceptance criteria.
• Interface with fabrication shops, suppliers, and engineering teams to ensure design intent and production quality.
• Recommend manufacturing methods, tooling strategies, and process improvements.
• Assist with rapid prototyping and iterative design refinement.
• Ensure work complies with applicable aerospace, aviation, and quality management standards where required.

Skills

Reverse engineering

Aerospace engineering knowledge

Quality engineering

Prototyping

Education

Bachelor's degree in Mechanical/Manufacturing/Aerospace

Tools

SolidWorks

Fusion 360

CATIA

Siemens NX

CMMs

Calipers

Micrometers

Laser scanners

Structured-light scanners

Job description

Zel Technologies seeks an experienced Senior Reverse Engineering Specialist to support evaluation, analysis, redesign, and validation of complex mechanical components. Remote and onsite work may be required depending on project scope.

The ideal candidate has 12+ years of related experience, a mechanical/aerospace engineering background, and hands‑on expertise in reverse engineering, GD&T, and DFM for manufacturability and cost reduction.