Failure Analysis Engineer

Failure Analysis Engineer

Hayward, California, United States- Full-time

Skydio is the leading US drone company and the world leader in autonomous flight, the key technology for the future of drones and aerial mobility. The Skydio team combines deep expertise in artificial intelligence, best-in-class hardware and software product development, operational excellence, and customer obsession to empower a broader, more diverse audience of drone users, from utility inspectors to first responders, soldiers in battlefield scenarios, and beyond.

About the role:

We are seeking a talented multi-disciplinary quality engineer to define, implement, and continuously improve quality processes. In this role, your contributions will directly drive product quality, speed to market, productivity, and profitability.

Position Summary

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.

Key Responsibilities

Failure Investigation & Root Cause Analysis

• 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

Diagnostic & Test Activities

• 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.

Reliability & Corrective Actions

• 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.

Component & Assembly Analysis

• 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.

Documentation & Reporting

• 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.

Cross-functional Collaboration

• Work closely with:

• Design Engineering

• Hardware Engineering

• Embedded Software Engineering

• Manufacturing Engineering

• Supplier Quality

• Reliability Engineering

• Production

• Customer Support

Required Qualifications

• Bachelor's or Master's degree in:

• Electronics Engineering

• Electrical Engineering

• Mechatronics

• Instrumentation Engineering

• Embedded Systems

• Aerospace Engineering (Electronics specialization preferred)

Experience

• 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.

Compensation: At Skydio, our compensation packages for regular, full-time employees include competitive base salaries, equity in the form of stock options, and comprehensive benefits packages. Compensation will vary based on factors, including skill level, proficiencies, transferable knowledge, and experience. Relocation assistance may also be provided for eligible roles. The annual base salary range for this position is $147,000 - $170,000*. Fundamentally, we believe that equity is the key to long-term financial growth, and we ensure all regular, full-time employees have the opportunity to significantly benefit from the company's success. Regular, full-time employees are eligible to enroll in the Company’s group health insurance plans. Regular, full-time employees are eligible to receive the following benefits: Paid vacation time, sick leave, holiday pay and 401K savings plan. This position and all associated benefits are subject to applicable federal, state, and local laws, as well as the Company’s policies and eligibility criteria.

*Compensation for certain positions may vary based on the position’s location.

At Skydio we believe that diversity drives innovation. We have created a multidisciplinary environment that embraces the power of diverse perspectives to create elegant solutions for complex problems. We are committed to growing our network of people, programs, and resources to nurture an inclusive culture.

Qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, protected veteran status, or other characteristics protected by federal, state or local anti-discrimination laws.

For positions located in the United States of America, Skydio, Inc. uses E-Verify to confirm employment eligibility. To learn more about E-Verify, including your rights and responsibilities, please visit https://www.e-verify.gov/