Role SummaryThis position develops the test capabilities and experimental evidence needed to assess the reliability of electrical hardware. You will evaluate PCB assemblies, power supplies, AC/DC and DC/DC converters, voltage regulators, and power distribution assemblies through controlled electrical and environmental testing.
A central part of the role is creating practical test solutions: designing and building custom jigs and fixtures, integrating instruments and electronic loads, writing automation, and tracking performance throughout accelerated stress testing. You will work directly with the Systems team to establish realistic operating conditions and evaluate how components, boards, and power modules behave within the complete system.
Electrical failure analysis is also part of the work. You will investigate abnormal behavior, reproduce failures, isolate suspect components or circuits, and collaborate with the Failure Analysis and Design teams to connect test results with failure mechanisms and verify corrective actions.
Key Responsibilities- Design, assemble, and troubleshoot custom electrical test jigs, fixtures, interface boards, load circuits, and wiring harnesses for power electronics and system reliability testing.
- Work directly with the Systems team to establish representative workloads, power sequencing, electrical interfaces, operating limits, and monitoring requirements.
- Translate product requirements and reliability risks into test plans with defined stress conditions, sample sizes, durations, measurements, and acceptance criteria.
- Build automated test setups integrating programmable power supplies, electronic loads, switching hardware, sensors, and data acquisition equipment.
- Develop Python or equivalent software for instrument control, test sequencing, continuous monitoring, fault capture, and analysis.
- Execute accelerated life testing, burn-in, powered temperature cycling, power/load cycling, and biased temperature/humidity testing based on the hardware and failure mechanisms being evaluated.
- Establish electrical baselines and monitor changes before, during, and after stress. Measurements may include efficiency, regulation, ripple and noise, transient response, startup/shutdown behavior, protection functions, and thermal derating.
- Investigate electrical failures using schematics, PCB layouts, component datasheets, and bench measurements to isolate shorts, opens, leakage, intermittent behavior, and performance degradation.
- Reproduce system-level anomalies in controlled experiments with the Systems team and correlate electrical results with physical failure-analysis findings.
- Use DOE, statistical reliability analysis, and physics-of-failure methods to assess degradation, compare design alternatives, and evaluate component or process changes.
- Partner with Design, Failure Analysis, Mechanical/Thermal Engineering, Quality, Manufacturing, and suppliers to validate corrective actions and communicate reliability risks.
- Maintain calibrated, repeatable test setups with appropriate electrical protection and interlocks.
- Document fixture designs, test procedures, results, and investigation findings so that methods can be reproduced and conclusions can guide engineering decisions.
Skills and Qualifications- 5+ years of experience in electrical testing, hardware validation, reliability engineering, or electrical failure analysis.
- Demonstrated ability to turn electrical test requirements into working laboratory setups, including custom fixtures, interface circuitry, wiring, and instrumentation.
- Strong knowledge of PCBAs, power conversion, voltage regulation, power distribution, and electronic circuit behavior.
- Practical experience with oscilloscopes, differential and current probes, programmable power supplies, electronic loads, multimeters, power analyzers, source measurement units, and data acquisition systems.
- Proficiency in Python, LabVIEW, or equivalent tools for test automation and data analysis.
- Strong circuit-debugging skills and the ability to interpret schematics, PCB layouts, and component specifications.
- Understanding of accelerated testing, electronics failure mechanisms, reliability statistics, and measurement uncertainty.
- Familiarity with relevant JEDEC and IPC test methods and qualification practices.
- Ability to collaborate directly with Systems engineers, communicate technical findings clearly, and manage multiple laboratory investigations.
- BS in Electrical Engineering, Computer Engineering, or a related technical discipline.
Desired Skills and Qualifications- Master's degree or PhD in Electrical Engineering, Computer Science, or a related field.
- Experience integrating electrical test fixtures with environmental chambers and automated monitoring systems.
- Hands-on work with high-current power modules, converters, and power delivery assemblies.
- Experience with board bring-up, system integration, embedded firmware, Linux-based test environments, and hardware communication interfaces.
- Knowledge of reliability concerns associated with power semiconductors, capacitors, magnetic components, connectors, and solder joints.
- Ability to interpret microscopy, thermal imaging, X-ray, and cross-sectional findings in the context of electrical failures.
Location: Sunnyvale, CA
The base salary range for this position is $190,000 to $230,000 annually. Actual compensation may include bonus and equity, and will be determined based on factors such as experience, skills, and qualifications.
