Senior Failure Analysis Engineer

Job description

Job responsibilities

• Perform failure analysis investigations on mechanical, electrical, and material, across components, subsystems, and complete aircraft.
• Perform in-depth failure analysis on both electrical (e.g., power distribution, connectors, wiring harnesses, motors) and electronics (e.g., PCBAs, ICs, sensors, communication circuits) to identify root causes of…
• Troubleshoot failures using schematics, circuit tracing, fault isolation techniques, and Design of Experiments.
• Apply advanced analytical techniques (e.g., SEM/EDS, X-ray, CT scan, TDR, OBIRCH, FTIR, FIB, cross-sectioning) to uncover complex failure modes.
• Proficient with standard electrical bench equipment: voltage sources, current loads, source meters, and oscilloscopes, curve tracer, thermal camera, etc.
• Translate physical failure evidence into actionable root-cause conclusions that drive design, process, and supplier improvements.
• Provide technical guidance on failure risks in ESCs, BMS, avionics systems, and sensors critical to aircraft performance.
• Collaborate with cross-functional teams (design, reliability, manufacturing, and suppliers) to drive corrective actions and prevent recurrence.

Job requirements

• 8+ years in failure analysis, senior-level experience preferred.
• Bachelor’s or Master’s degree in Electrical Engineering, or related field.
• Proficient in 8D problem-solving methodology.
• Excellent analytical and troubleshooting skills.
• Hands-on experience with electrical FA tools, non destructive, and destructive FA methods (oscilloscopes, curve tracers, TDR, SEM/EDX, FTIR, CT Scan, etc.).
• Preferred hands-on failure analysis experience with key aircraft HW subsystems/components including, BMS, ESC, Avionics, Servo, and sensors.
• Experience reviewing PCB layouts and schematics.
• Experience with PCB/PCBA assembly and SMT processes, including identifying failures related to assembly or soldering defects.