Senior Engineer, Failure Analysis (R3520)

Founded in 2015, Shield AI is a venture-backed defense technology company with the mission of protecting service members and civilians with intelligent, autonomous systems. Its products include Hivemind Enterprise—EdgeOS, Pilot, Commander, and Forge—as well as V-BAT and Sentient Vision Systems (wide-area motion imaging software). With offices in San Diego, Dallas, Washington, D.C., Abu Dhabi (UAE), Kyiv (Ukraine), and Melbourne (Australia), Shield AI’s technology actively supports U.S. and allied operations worldwide.  For more information, visit www.shield.ai. Follow Shield AI on LinkedIn, X and Instagram.    

Shield AI is seeking a skilled and detail-oriented Failure Analysis Engineer to lead root cause investigations for avionics hardware. This role will be responsible for conducting hands-on failure analysis of circuit cards, sensors, and electronic assemblies returned from production, test, and field environments. The ideal candidate has a strong background in electronics, structured problem-solving, and experience with AS9100 or similar aerospace/defense standards.

• Conduct thorough failure analysis on electronic assemblies and components (PCBA level) returned from production, customers, or validation.
• Perform electrical testing and fault isolation using oscilloscopes, multimeters, and ICT/FCT systems.
• Analyze process-related issues such as solder bridging, tombstoning, cold joints, or voids in BGA and QFN packages.
• Document findings in detailed Failure Analysis Reports, including photos, data, and corrective action recommendations.
• Collaborate with design, test, and manufacturing engineering teams to improve DFM/DFT and overall reliability.
• Support CAPA (Corrective and Preventive Action) and continuous improvement initiatives.
• Maintain failure database and trend analysis for recurring issues.

• Bachelor’s degree in Electronics, Electrical, Materials, or Mechanical Engineering.
• 2–5+ years of experience in failure analysis or reliability engineering, preferably in a PCBA or EMS environment.
• Proficient in tools: X-ray inspection, SEM/EDS, AOI, ICT, thermal analysis, microscopes.
• Understanding of SMT, wave soldering, reflow processes, ICT, and FTs.
• Experience with IPC standards (e.g., IPC-A-610, IPC-7711/7721) is a plus.
• Experience with FA software, report automation tools, or statistical tools like Minitab.

• Strong analytical, documentation, and communication skills.
• Familiarity with Six Sigma, 8D, 5 Whys, or FMEA methodology.
• Knowledge of RoHS/REACH compliance, ESD standards, and component de-rating.

Full-time regular employee offer package:

Pay within range listed + Bonus + Benefits + Equity

Temporary employee offer package:

Pay within range listed above + temporary benefits package (applicable after 60 days of employment)

Salary compensation is influenced by a wide array of factors including but not limited to skill set, level of experience, licenses and certifications, and specific work location. All offers are contingent on a cleared background and possible reference check. Military fellows and part-time employees are not eligible for benefits. Please speak to your talent acquisition representative for more information.

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Shield AI is proud to be an equal opportunity workplace and is an affirmative action employer. We are committed to equal employment opportunity regardless of race, color, ancestry, religion, sex, national origin, sexual orientation, age, marital status, disability, gender identity or Veteran status. If you have a disability or special need that requires accommodation, please let us know.