Reliability Test & Failure Analysis Technician

About the Role

We are seeking a hands-on Reliability Test & Failure Analysis Technician to support environmental, mechanical, electrical, and long-duration reliability testing of power electronics assemblies used in Solid State Transformer (SST) systems. This role is responsible for preparing test samples, building and maintaining test fixtures, operating environmental and vibration test equipment, monitoring long-term reliability tests, documenting results, and supporting failure analysis activities.

The ideal candidate is detail-oriented and experienced with power electronics hardware, environmental chambers, vibration systems, laboratory instrumentation, and test equipment. The technician will work closely with Reliability, Failure Analysis, Quality, Manufacturing, and Facilities teams to execute reliability qualification, burn-in, and operational reliability testing.

What You'll Do

Reliability Test Setup & SamplePreparation

• Prepare, inspect, document, and track test samples including PSM boards, and critical sub-assemblies and systems.
• Perform board bring-up, functional verification, pre- and post-test inspections, and hardware teardown activities.
• Maintain sample traceability, collect measurements, capture photographs, and document hardware condition before, during, and after testing.
• Coordinate rework and return of hardware to engineering teams for analysis.

Test Fixtures & Equipment Support

• Build, modify, maintain, and improve reliability test fixtures and support equipment.
• Install, verify, and maintain power supplies, thermocouples, temperature, and humidity sensors, and data collection equipment.
• Support burn-in and Operational Reliability Test (ORT) development through fixture improvements, repeatability verification, and sample processing.

Environmental & Reliability Testing

• Operate environmental chambers, vibration systems, and reliability test equipment supporting Temperature Cycling, THB, Condensation, HTOL, RDT, and other qualification tests.
• Perform safety reviews, functional verification, and ensure hardware remains within approved operating limits throughout testing.
• Install test samples and instrumentation, verify fixture integrity and torque requirements, and conduct pre- and post-test inspections.
• Monitor test progress, record alarms, excursions, downtime, interruptions, and time-at-condition data, and document anomalies.
• Assemble, operate, and maintain SST reliability test systems, including power, cooling, instrumentation, data collection, and communications equipment.
• Execute approved procedures, perform routine inspections, troubleshoot issues, and escalate abnormal conditions as needed.

Failure Analysis Support

• Respond to hardware failures during testing by securing failed units and preserving failure evidence.
• Perform preliminary fault isolation, documentation, and sample preparation for engineer-led investigations.
• Maintain detailed records and photographic evidence to support root cause analysis.

Lab Operations & Equipment Maintenance

• Perform preventive maintenance on environmental chambers, vibration systems, thermal equipment, instrumentation, and laboratory support equipment.
• Troubleshoot mechanical, electrical, refrigeration, and instrumentation issues affecting test execution.
• Coordinate equipment calibration, sensor verification, and certification activities.
• Work with Facilities and external vendors to maintain laboratory infrastructure, including electrical power, cooling water, compressed air, and network services.
• Support laboratory safety, equipment uptime, and continuous improvement initiatives.

What you'll Bring

• 3+ years of experience in reliability testing, environmental testing, failure analysis, manufacturing test, electronics laboratories, or related technical operations.
• Experience operating environmental chambers, vibration systems, power supplies, DAQ equipment, and laboratory instrumentation.
• Experience with electronic assemblies, power electronics, or industrial electrical equipment is preferred.
• Ability to read schematics, wiring diagrams, assembly drawings, and engineering documentation.
• Working knowledge of thermocouples, temperature monitoring, insulation resistance and leakage-current measurements, electrical safety practices, and reliability test methods including Temperature Cycling, THB (85°C/85% RH), Condensation Testing, Burn-In, HALT/HASS, Vibration Testing, and Reliability Demonstration Testing.
• Strong troubleshooting and diagnostic skills related to power electronics hardware, test fixtures, instrumentation, and environmental test systems.
• Associate degree in Electronics Technology, Electrical Technology, Mechanical Technology, Mechatronics, HVAC, or a related technical discipline, or equivalent military or industry experience.
• IPC certification, electrical technician training, or EPA Section 608 certification is a plus.

Communication & Documentation

• Strong written and verbal communication skills.
• Ability to maintain accurate test logs, inspection records, maintenance records, and failure analysis documentation.
• Comfortable communicating technical findings to engineers, technicians, vendors, and management.

Physical Requirements & Working Conditions

• Ability to lift up to 50 lbs and safely move test hardware and fixtures.
• Comfortable working around energized power electronics, environmental chambers, vibration systems, and laboratory equipment while following established safety procedures.
• Ability to stand, bend, climb ladders, and work inside large environmental test chambers when required.
• Willingness to support long-duration testing activities that may occasionally require off-hours monitoring, troubleshooting, or test recovery support.