Failure Analysis Engineer

Skydio•Hayward, CA

11h•$147,000 - $170,000

About The Position

We are seeking a highly motivated and detail-oriented Failure Analysis Engineer to investigate, diagnose, and resolve failures in drone systems and subsystems. The ideal candidate will possess strong expertise in electrical, electronic, and electromechanical components, including PCBs, power electronics, batteries, cameras, sensors, communication modules, motors, ESCs, GPS, IMUs, and embedded systems. The role involves performing systematic root cause analysis, collaborating with cross-functional teams, driving corrective and preventive actions (CAPA), and improving product reliability throughout the product lifecycle.

Requirements

Bachelor's or Master's degree in: Electronics Engineering, Electrical Engineering, Mechatronics, Instrumentation Engineering, Embedded Systems, Aerospace Engineering (Electronics specialization preferred).
3–8 years of experience in failure analysis, reliability engineering, hardware validation, or product quality.
Experience in UAV, drone, robotics, automotive electronics, aerospace, consumer electronics, or industrial electronics is highly preferred.
Obtaining FAA Part 107 certification within the first 60 days of employment is strongly encouraged for all Skydio employees and required for certain positions.

Responsibilities

Perform detailed failure analysis on returned products, manufacturing defects, field failures, and reliability test failures.
Investigate failures related to: Printed Circuit Boards (PCB/PCBA), Power distribution systems, Battery Management Systems (BMS), Electronic Speed Controllers (ESC), Brushless DC motors, Cameras and imaging systems, Vision modules, GPS modules, IMU (Accelerometer, Gyroscope, Magnetometer), Barometers and other environmental sensors, RF communication modules, Flight controllers, Wiring harnesses and connectors, Electromechanical assemblies.
Conduct systematic root cause analysis using methodologies such as: 8D, 5 Why, Fishbone Diagram, Fault Tree Analysis (FTA), Failure Mode and Effects Analysis (FMEA), Pareto Analysis.
Develop and execute diagnostic procedures for failed products.
Perform electrical measurements using: Oscilloscope, Digital Multimeter, Logic Analyzer, Spectrum Analyzer (preferred), Power Analyzer, Thermal Camera.
Interpret circuit schematics, PCB layouts, and wiring diagrams.
Conduct functional, environmental, and stress testing to reproduce failures.
Identify failure trends using field and production data.
Recommend design improvements to enhance product reliability.
Drive corrective and preventive actions (CAPA) with Design, Manufacturing, Supplier Quality, and Production teams.
Verify effectiveness of implemented corrective actions.
Analyze component-level failures including: ICs, MOSFETs, Voltage regulators, Capacitors, Inductors, Sensors, Connectors, Cameras, RF modules.
Evaluate solder joint quality, PCB defects, ESD damage, overheating, corrosion, vibration damage, and mechanical failures.
Prepare comprehensive failure analysis reports with: Root cause, Evidence, Corrective actions, Preventive actions, Risk assessment.
Maintain failure databases and reliability metrics.
Present findings to engineering and management teams.
Work closely with: Design Engineering, Hardware Engineering, Embedded Software Engineering, Manufacturing Engineering, Supplier Quality, Reliability Engineering, Production, Customer Support.