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Staff Engineer, Electrical Failure Analysis (R4593)

Leads failure analysis investigations for avionics hardware including PCBAs, harnesses, and interconnects. Performs root cause analysis using structured methods and drives corrective actions. Requires 8+ years in aerospace/defense hardware reliability and hands-on FA techniques.

150k – 220kDallas, TXHardware EngineeringOnsite8+ YOE

About the role

Responsibilities

  • Lead failure analysis investigations for avionics hardware, including PCBAs (digital, analog, power, mixed-signal), harnesses, connectors, and interconnects.
  • Perform root cause analysis (RCA) using structured methodologies (8D, 5-Why, Fishbone, Fault Tree, etc.).
  • Conduct and/or oversee electrical, mechanical, and environmental failure analysis.
  • Collaborate with design engineers to identify design vulnerabilities, manufacturing and suppliers on process-related issues.
  • Work closely with cross-functional teams (reliability, mechanical, embedded, software, production, supply chain, etc.).
  • Drive design, process, and supplier corrective actions to closure.
  • Author clear, data-driven failure analysis reports and present findings to technical and program leadership.
  • Mentor junior engineers and help establish best practices for failure analysis and reliability.

Requirements

  • Bachelor’s degree in electrical engineering or equivalent work experience.
  • 8+ years of experience in failure analysis, reliability, or hardware debug for aerospace, defense, or high-reliability electronics.
  • Strong technical fundamentals.
  • Experienced with cross-sectioning, microscopy, X-ray, and other FA techniques.
  • Strong hands-on experience with PCBA failure mechanisms (solder joints, vias, components, PCB materials), harnesses, connectors, crimping, shielding, and interconnect reliability.
  • Demonstrated track record of extreme ownership, working hard, and delivering outstanding outcomes.
  • Ability to independently drive investigations from symptom to root cause.

Skills

PcbaRoot Cause AnalysisCross-SectioningMicroscopyX-RaySolder JointsViasPcb MaterialsHarnessesConnectorsCrimpingShieldingAvionicsEmbedded SystemsPower Systems

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