Sr. Reverse Engineering Specialist

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

* This position is eligible for a $500 ZelTech Non-Employee Referral fee. ContactZelTech Recruiters for questions concerning this matter. *

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Job Summary:

We are seeking an experienced Senior Reverse Engineering Specialist to support the evaluation, analysis, redesign, and validation of complex mechanical components and assemblies. This is an on-call/project base engagement position ideal for a highly skilled engineering professional with strong hands‑on experience in reverse engineering, aviation-grade quality standards, additive manufacturing, and design for manufacturability (DFM). The ideal candidate combines deep mechanical engineering knowledge with practical manufacturing and inspection expertise and is comfortable working independently on highly technical projects with varying scope and urgency. This candidate is also a practical problem‑solver who can move fluidly between engineering analysis, physical inspection, prototyping, and manufacturing execution. This role is best suited for someone who enjoys complex technical challenges, precision mechanical work, and developing high‑quality production‑ready solutions from existing hardware or incomplete technical data. Remote and onsite work may be required depending on project scope.

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.

Requirements:

• Must be a US citizen.
• 12+ years related experience.
• Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Aerospace Engineering, or equivalent practical experience.
• Strong experience in reverse engineering mechanical systems and precision components.
• Prior experience in quality control, quality assurance, or manufacturing quality engineering.
• Experience with additive manufacturing technologies including FDM, SLA, SLS, metal printing, or hybrid manufacturing workflows.
• Strong understanding of prototyping methods, machining processes, GD&T, tolerance stack‑up, and DFM principles.
• Proficiency with CAD software such as SolidWorks, Fusion 360, CATIA, Siemens NX, or similar platforms.
• Familiarity with metrology equipment including CMMs, calipers, micrometers, laser scanners, and structured‑light scanning systems.
• Experience generating technical drawings and production documentation.
• Knowledge of materials, heat treatment, coatings, and mechanical performance characteristics.
• Ability to work independently with minimal supervision and adapt quickly to new technical challenges.
• Successful background and drug screening check.

Preferred Requirements:

• Ability to obtain a TS/SCI clearance with a CI polygraph.
• Background in aviation or aerospace component design.
• FAA‑regulated or aerospace manufacturing environments
• AS9100 or ISO 9001 quality systems.
• Failure analysis and corrective action processes.
• Small‑batch production and rapid product development.
• Fixture and tooling design.
• CAM programming or CNC manufacturing workflows.

Physical Demands or Work Environment:

The work environment characteristics and physical demands described here are representative of those an employee encounters while performing the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

• The majority of the time is spent in an office setting.
• Occasionally lift and/or move up to 25 pounds.
• Specific vision abilities required include close vision, distance, vision, color vision and ability to adjust focus.

About ZelTech:

Founded in 1988 by Ret. Col. Jack L. Ezzell Jr., Zel Technologies is a trusted leader in national security, providing comprehensive research, development, engineering, and operational support to the Department of Defense, the Intelligence Community, and federal agencies. Originally focused on leveraging operational and software expertise to improve time‑critical targeting capabilities for the military, the company advanced its capabilities to provide scientific and HUMINT expertise for CBRNE collection and analysis. In the wake of 9/11, Zel Technologies rapidly expanded its capabilities to provide turnkey ISR support services to US Special Operations Forces (SOF), as well as advanced technical & operational intelligence, physical & data science, and engineering support services to the greater Intelligence and SOF Communities supporting global counterterrorism and CWMD operations.

Today, Zel Technologies remains at the forefront of intelligence missions, advancing CWMD and global counterterrorism efforts, while also addressing emerging threats posed by near‑peer adversaries. Our team remains committed to delivering adaptive, innovative, and cost‑effective solutions across multiple domains, in alignment with the mission priorities of the U.S. Government and its partner nations.

Our Mission:

Through our commitment to innovation and quality, our skilled teams deliver robust, technology driven solutions and insights that empower our customers to overcome complex challenges and achieve their mission objectives.

Our Workforce:

ZelTech team members represent a wide range of backgrounds, skills, experience, and personalities bound together by common objectives and mutual respect. You will join a caring community of professional, including manymilitary veterans who challenge and support each other in seeking the right solutions to important matters.

ZelTech is an equal opportunity employer and does not discriminate based on race, color, religion, creed, sex, age, sexual orientation, national origin, disability, marital status, military status, genetic predisposition, or any other basis protected by law.