Reliability Test Engineer
Conducts environmental reliability testing for electronic flight hardware, from test-plan development and fixture design through instrumentation, equipment operation, failure investigation, and reporting. Requires hands-on environmental testing experience, engineering education, CAD and data-acquisition expertise, with Python and FEA experience preferred.
About the job
Responsibilities
- Operate and continuously improve an environmental test lab for electronics, including HALT/HASS chambers, thermal-humidity chambers, vibration/shock equipment, and data acquisition systems.
- Develop lab procedures for environmental test equipment, test setup and teardown, data acquisition, and reporting.
- Perform thermal cycling, temperature-humidity soaks, HALT, HASS, vibration, and shock testing on electronic products.
- Define test plans, including stress profiles, sample sizes, and pass/fail criteria.
- Design and model test fixtures in CAD; instrument hardware with thermocouples, accelerometers, strain gauges, and humidity sensors.
- Configure data acquisition systems, program and load environmental chambers, operate equipment, and monitor and investigate failures.
- Automate data acquisition, document results, and create plots and visualizations for qualification and disposition decisions.
- Manage equipment scheduling, lab consumables, instrumentation, adhesives, fasteners, fixtures, maintenance, organization, and safety.
- Coordinate with external laboratories as needed and educate stakeholders on environmental testing and design-for-test practices.
- Collaborate with interdisciplinary teams from product concept through production and manage technical projects.
Requirements
- 2+ years of experience with environmental testing, including temperature cycling, vibration, HALT, and HASS.
- Bachelor's degree in Mechanical Engineering, Electrical Engineering, or Reliability Engineering.
- Proficiency with CAD modeling software such as ANSYS SpaceClaim, NX, or SolidWorks.
- Knowledge of data acquisition equipment and instrumentation, including thermocouples, accelerometers, humidity sensors, and strain gauges.
- Familiarity with electronics, including PCBs, PCBAs, electronic components, and moving mechanical assemblies.
- Knowledge of failure mechanisms including solder fatigue, intermetallic growth, conductive anodic filaments, tin whiskers, electromigration, and corrosion.
- Experience working with interdisciplinary product design teams and managing technical projects.
- Familiarity with IPC, JEDEC, MIL, and ASTM test standards.
- Strong problem-solving, attention to detail, and written and verbal communication skills.
Nice-to-Haves
- 5+ years of experience in reliability testing.
- Familiarity with Weibull statistics, accelerated life test design, HALT, and HASS.
- Master's degree in Mechanical Engineering, Electrical Engineering, or Reliability Engineering.
- Experience managing an environmental test lab.
- Familiarity with PCB fabrication, SMT, and polymerics application manufacturing processes.
- Proficiency with FEA software such as ANSYS Mechanical, Siemens Simcenter, or Abaqus.
- Proficiency in Python, including NumPy, Pandas, SciPy, Plotly, and Matplotlib.
Skills
Environmental Testing, Halt, Hass, Thermal Cycling, Vibration Testing, Shock Testing, CAD, Ansys Spaceclaim, Nx, Solidworks, Data Acquisition, Python, NumPy, pandas, Scipy
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