Sr. Reverse Engineering Specialist

Zel Technologies•Cape Canaveral Space Force Station, FL, Cape Canaveral, FL, US, FL

5d•Hybrid

About The Position

This position is eligible for a $500 ZelTech Non-Employee Referral fee. Contact ZelTech Recruiters [[email protected]] for questions concerning this matter. Join Our Talent Community to Stay Connected! 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.

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.

Nice To Haves

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.

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.