Failure Analysis Engineer Jobs in Virginia (NOW HIRING)

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.

Skydio’s cameras are critical to autonomous navigation, situational awareness, and capturing high-quality imagery in demanding environments. As a Product Design Engineer, you will help design, prototype, test, and refine the mechanical systems that enable our camera modules to perform reliably.

You will work hands‑on with camera components and assemblies, collaborating closely with mechanical, optical, electrical, reliability, manufacturing, and supplier engineering teams. This is an individual‑contributor role suited to an engineer who enjoys detailed mechanical design, rapid prototyping, laboratory work, and methodical problem‑solving.

• Create 3D CAD models and production‑ready 2D drawings for camera parts, assemblies, test equipment, and related mechanical systems.
• Support the mechanical design and integration of camera modules, lenses, image sensors, actuators, thermal solutions, electronics, flex circuits, seals, and structural components.
• Design and build prototypes to evaluate new concepts, integration approaches, and mechanical architectures.
• Design test jigs, fixtures, and measurement setups for camera development, characterization, assembly, and validation.
• Perform tolerance analyses to evaluate fit, alignment, optical positioning, assembly variation, and mechanical performance.
• Prototype components and assemblies using methods such as 3D printing, CNC machining, and hands‑on assembly.
• Support finite element analysis, including the preparation of models, definition of boundary conditions, correlation with physical testing, and interpretation of results.
• Plan and conduct laboratory testing, analyze results, and communicate findings through clear engineering reports.
• Characterize camera components and assemblies, including dimensions, torque, force, stiffness, thermal performance, and resistance to heat, water, and other environmental conditions.
• Investigate mechanical and electromechanical failures, identify root causes, and help develop and validate corrective actions.
• Support reliability and optical testing, including test setup development, sample preparation, execution, data collection, and failure analysis.
• Work with manufacturing, quality, supply chain, and external vendors to support component fabrication, inspection, assembly, and design improvements.
• Contribute throughout the product‑development cycle, from early concepts and prototypes through design validation, pre‑production, and mass‑production support.

What Makes You a Good Fit:

• Master’s degree in mechanical engineering or a related discipline, or equivalent practical experience.
• Experience applying mechanical‑engineering fundamentals and analytical problem‑solving to the development of physical products or electromechanical systems.
• Proficiency in 3D CAD and the ability to create clear, well‑constructed mechanical part and assembly drawings. Experience with CATIA is strongly preferred.
• Working knowledge of geometric dimensioning and tolerancing, tolerance analysis, materials, and common manufacturing processes.
• Experience with rapid prototyping methods such as 3D printing, CNC machining, and hands‑on mechanical assembly.
• Familiarity with designing parts for processes such as injection molding, CNC machining, metal forming, or casting.
• Practical laboratory skills and confidence using mechanical measurement and test equipment.
• Ability to document test methods, analyze data, and communicate conclusions clearly.
• A detail‑oriented and methodical approach to debugging, characterization, and failure analysis.
• Ability to collaborate effectively across mechanical, optical, electrical, reliability, manufacturing, and supplier teams.
• Curiosity, initiative, and a willingness to learn while working in a fast‑paced product‑development environment.
• A strong interest in cameras, precision mechanisms, robotics, drones, or imaging systems.

• 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. 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.

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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/