Failure Analysis Engineer Jobs in Washington (NOW HIRING)

We are seeking a Failure Mode Investigation Engineer with a bachelor's degree in materials science, chemical engineering, mechanical engineering, chemistry, or a related field. In this role, you will investigate product and process failures across electronic assemblies, coatings, polymers, and substrate interfaces. You will combine analytical chemistry, materials characterization, and electrical test methods to determine root cause, support corrective actions, and help prevent recurrence in a regulated R&D and manufacturing environment.

• Conduct failure analysis and support investigations on electronic components, assemblies, and bonded/coated surfaces, addressing issues such as adhesive debonding, corrosion, delamination, electrical opens/shorts, and battery failures.
• Document findings in clear investigation reports with evidence, conclusions, and recommended corrective/preventive actions.
• Characterize failed interfaces and bulk materials using SEM/EDS, FTIR, contact angle, profilometry, cross-section microscopy, and other lab techniques.
• Interpret chemical mechanisms affecting adhesion, curing, oxidation, moisture ingress, and interphase degradation.
• Evaluate surface preparation, primers, epoxies, plasma activation, and coating processes against failure modes.
• Perform electrical diagnostics on failed devices, including continuity, impedance, functional tests, leakage, and signal integrity.
• Correlate electrical failure signatures with physical/materials evidence, such as bond line defects, contamination, and mechanical stress.
• Support design-for-reliability inputs based on observed field and manufacturing failures.
• Collaborate with R&D Engineering, Process, and Quality teams on validation protocols, DOEs, and acceptance criteria.
• Support nonconformance, supplier quality, and customer complaint investigations.
• Present technical findings to engineering and quality teams, maintaining traceability per quality system requirements.

• 1–3 years of experience in failure analysis, materials testing, electronics troubleshooting, or process engineering (internships/co-op experience considered).
• Hands-on experience with at least some of microscopy, spectroscopy, electrical test equipment, or mechanical/adhesion testing.
• Working knowledge of polymers, adhesives, coatings, metals/ceramics, or electronic assembly materials.
• Strong written and verbal communication skills, with the ability to explain technical results to non-specialists.
• Detail-oriented with solid data interpretation and documentation habits.

• Experience in failure analysis, root cause investigation, and CAPA support.
• Proficiency with SEM, EDS, optical microscopy, cross-section analysis, and FTIR.
• Understanding of surface characterization and failure mode investigation.
• Experience with DOE, polymer analysis, and nonconformance investigations.

This role is primarily laboratory-based with typical weekday hours. The role offers some flexibility, as testing may require early or late shifts. The position involves preparing samples for imaging, conducting tests, compiling data, and understanding project needs. This is a new role created to understand the true failure rate of devices, offering exposure to various aspects of failure mode investigations and collaboration with engineering teams.

This is a Contract to Hire position based out of Germantown, MD.

The pay range for this position is $31.25 - $36.06/hr.

Eligibility requirements apply to some benefits and may depend on your job classification and length of employment. Benefits are subject to change and may be subject to specific elections, plan, or program terms. If eligible, the benefits available for this temporary role may include the following: • Medical, dental & vision • Critical Illness, Accident, and Hospital • 401(k) Retirement Plan – Pre-tax and Roth post-tax contributions available • Life Insurance (Voluntary Life & AD&D for the employee and dependents) • Short and long-term disability • Health Spending Account (HSA) • Transportation benefits • Employee Assistance Program • Time Off/Leave (PTO, Vacation or Sick Leave)

This is a fully onsite position in Germantown,MD.

This position is anticipated to close on Aug 10, 2026.

About Actalent

Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 20,000 consultants and 5,000 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500. We are proud to be an Engineering News-Record (ENR) Top 500 Design Firm for our engineering design services and a ClearlyRated Best of Staffing® winner for both client and talent service.

The company is an equal opportunity employer and will consider all applications without regard to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law.

If you would like to request a reasonable accommodation, such as the modification or adjustment of the job application process or interviewing process due to a disability, please email actalentaccommodation@actalentservices.com for other accommodation options.

San Francisco Fair Chance Ordinance: Pursuant to the San Francisco Fair Chance Ordinance, for all positions located in the city and county of San Francisco, we will consider for employment qualified applicants with arrest and conviction records.

Massachusetts Lie Detector: It is unlawful in Massachusetts to require or administer a lie detector test as a condition of employment or continued employment. An employer who violates this law shall be subject to criminal penalties and civil liability.

Use of Artificial Intelligence (AI): We may use Artificial Intelligence (AI) to support parts of our hiring process, including sourcing, screening, and evaluating candidates. AI helps assess applications and qualifications, but final decisions are made by our hiring team. By applying, you acknowledge and agree that your application may be reviewed using AI tools.