Sr. PCB Reliability Engineer

About the role

This position supports the Starshield program, which applies Starlink technology to national security, earth observation, and communication missions. You will manage the lifecycle of printed circuit boards for satellite and ground hardware to ensure high performance and quality standards. The role requires deep collaboration with cross-functional teams to translate program requirements into robust hardware solutions. You will act as a technical authority on PCB reliability throughout the design, build, and sustainment phases. Success in this position depends on your ability to predict failure modes and prevent them before they impact mission timelines. You will drive the adoption of reliability best practices across the organization. This position is critical for maintaining the integrity of hardware in demanding environments. Your work will directly influence the readiness and performance of space-based systems.

Key facts

What you'll do

• Define and develop PCB stackups for new hardware designs in alignment with performance and reliability targets.
• Introduce new materials while coordinating with design and supply chain teams to validate compatibility and risk.
• Build test plans and lead reliability campaigns for mass production to verify long-term performance under stress.
• Oversee design for manufacturing releases and manage vendor communication to resolve process deviations.
• Analyze production data to improve quality, output, and cost efficiency using statistical and empirical methods.
• Advise design teams on manufacturability improvements to optimize yield and reduce field failure rates.
• Conduct root-cause analysis for reliability failures and implement corrective measures to prevent recurrence.
• Develop and maintain reliability models that inform decision-making throughout the product lifecycle.
• Partner with test engineering groups to ensure validation methods align with reliability objectives.
• Document procedures, findings, and recommendations to support audits, certifications, and continuous improvement.
• Track key reliability metrics and present insights to technical and executive stakeholders.
• Support the integration of emerging technologies into existing hardware frameworks while managing risk.
• Ensure all activities comply with program requirements, standards, and regulatory constraints.
• Drive the execution of reliability tasks on schedule to support critical program milestones.

Requirements

• Bachelor degree in electrical, chemical, materials, or manufacturing engineering.
• Minimum 5 years of professional experience in PCB fabrication or reliability in a demanding technical environment.
• Ability to work extended hours and weekends when project milestones require it to protect delivery commitments.
• Willingness to travel up to 25 percent of the time to support program activities and stakeholder engagement.
• Must meet ITAR requirements as a U.S. citizen, permanent resident, refugee, or asylee to access controlled programs.
• Demonstrated capability to interpret and apply IPC and other relevant manufacturing standards.
• Willingness to maintain active security clearance status and comply associated with pre-employment and random drug and alcohol testing.
• Proven experience working with cross-functional teams to resolve complex technical challenges.
• Strong attention to detail and accuracy in documentation, analysis, and reporting.

Nice to have

• Expertise in industry PCB fabrication processes and materials to accelerate design for reliability initiatives.
• Proficiency with IPC manufacturing standards to ensure compliance and quality alignment.
• Experience with failure analysis tools including cross-sectioning, polishing, and X-ray for thorough investigation.
• Knowledge of statistical methods such as design of experiments and process capability analysis to quantify risk.
• Proven track record of using data to drive systemic improvements across the hardware lifecycle.
• Strong verbal and written communication skills to convey technical concepts to diverse audiences.

Skills & tools

• PCB design and fabrication methodologies
• Failure analysis techniques involving X-ray, cross-section, and polishing
• Statistical process control methods
• IPC standards for manufacturing and acceptability
• Design for manufacturing (DFM) principles and practices

Practical notes

• Salary range: $135,000 to $195,000 per year.
• Active security clearances receive a 10 percent differential, up to $20,000 annually, once briefed into classified programs.
• Compensation includes potential stock options, long-term cash awards, discretionary bonuses, and an Employee Stock Purchase Plan.
• Benefits include medical, dental, vision, 401(k), disability, life insurance, and paid parental leave.
• Vacation policy includes 3 weeks of paid time off plus 10 or more paid holidays and accrued sick leave.
• Active clearance holders are subject to pre-employment and random drug and alcohol testing.