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Failure Analysis Engineer Jobs (NOW HIRING)

IOActive

Failure Analysis Engineer

Seattle, WA · On-site

$100K - $150K/yr

We are seeking a Failure Analysis Engineer who will work with other team members to deliver the highest quality results to IOActive's clients throughout the world. Who you are: Our experts operate at ...

TSMC

Failure Analysis Engineer

Phoenix, AZ · On-site

Failure Analysis Engineer Join TSMC Arizona, a world-class leader in semiconductor manufacturing, where innovation drives the future. As part of our team, you'll work alongside top talent in a ...

TSMC

Failure Analysis Engineer

Phoenix, AZ

Failure Analysis Engineer Join TSMC Arizona, a world-class leader in semiconductor manufacturing, where innovation drives the future. As part of our team, you'll work alongside top talent in a ...

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Failure Analysis Engineer information

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$45.5K

$93.2K

$135.5K

How much do failure analysis engineer jobs pay per year?

As of Jun 25, 2026, the average yearly pay for failure analysis engineer in the United States is $93,179.00, according to ZipRecruiter salary data. Most workers in this role earn between $70,000.00 and $118,000.00 per year, depending on experience, location, and employer.

What is the difference between Failure Analysis Engineer vs Materials Engineer?

AspectFailure Analysis EngineerMaterials Engineer
Required CredentialsBachelor's or Master's in Engineering, certifications like ASQ CQE or FAIBachelor's or Master's in Materials Science or Engineering, similar certifications
Work EnvironmentLaboratories, manufacturing plants, quality assurance settingsResearch labs, manufacturing facilities, product development
Industry UsageAutomotive, electronics, aerospace, manufacturingMaterials development, testing, quality control across industries

Failure Analysis Engineers focus on diagnosing product failures to improve quality, often working in labs and manufacturing settings. Materials Engineers develop and test materials used in products, ensuring durability and performance. While both roles require similar credentials and work environments, Failure Analysis Engineers specialize in failure diagnostics, whereas Materials Engineers focus on material development and testing.

What engineers make $300,000 a year?

Senior failure analysis engineers with extensive experience, specialized skills in materials and failure modes, and often advanced certifications can earn $300,000 or more annually. High salaries are typically found in industries like aerospace, semiconductor, or energy, especially for those in leadership roles or with significant technical expertise.

What Does a Failure Analysis Engineer Do?

Failure analysis engineers check and identify problems associated with business processes. These errors primarily take place in electrical systems. Failure analysis engineers determine the cause of equipment failure and decide on an action plan to avoid similar issues in the future. Daily responsibilities include conducting tests on electrical systems to determine usability and life cycle, performing preventative maintenance, and conducting emergency maintenance on electrical components. Qualifications typically include a master’s degree in mechanical or electrical engineering, but most employers also provide on-the-job training.

What are some common challenges faced by Failure Analysis Engineers, and how can they be addressed?

Failure Analysis Engineers often encounter challenges such as limited access to failed components, incomplete failure histories, and tight deadlines for root cause identification. Overcoming these challenges requires strong attention to detail, effective communication with cross-functional teams, and creative problem-solving skills. Building a robust process for data collection and collaborating closely with manufacturing, design, and quality teams can help ensure thorough investigations and more accurate recommendations for corrective actions.

What are the key skills and qualifications needed to thrive as a Failure Analysis Engineer, and why are they important?

To thrive as a Failure Analysis Engineer, you need a solid background in materials science, electrical or mechanical engineering, and experience with analytical and diagnostic techniques, typically supported by a relevant engineering degree. Familiarity with laboratory tools such as scanning electron microscopes (SEM), X-ray analysis systems, and failure analysis software is common, and certifications like Six Sigma can be beneficial. Strong problem-solving skills, attention to detail, and effective communication are crucial soft skills for clearly documenting findings and collaborating with cross-functional teams. These skills and qualities are essential to accurately identify root causes of failures, drive product improvements, and minimize costly defects in manufacturing processes.

What do failure analysis engineers do?

Failure analysis engineers investigate the causes of product or component failures by examining materials, manufacturing processes, and operational conditions. They use tools such as microscopy, testing equipment, and data analysis to identify root causes and recommend improvements to prevent future failures. This role often requires strong problem-solving skills and knowledge of engineering principles.

How much does a failure analysis engineer make at AMD?

A failure analysis engineer at AMD typically earns between $80,000 and $130,000 annually, depending on experience, location, and level of expertise. Salaries may also include bonuses and benefits, and the role often requires knowledge of failure analysis tools and semiconductor testing processes.

What does a Failure Analysis Engineer do?

A Failure Analysis Engineer investigates the causes of failures in products, components, or systems to determine why they did not perform as expected. They use various analytical techniques such as microscopy, spectroscopy, and stress testing to identify defects or issues. Their work helps manufacturers improve product reliability, prevent future failures, and enhance overall quality. These engineers often collaborate closely with design, manufacturing, and quality assurance teams to implement corrective actions based on their findings.

What engineers make $500,000?

Senior failure analysis engineers with extensive experience, specialized skills in materials and failure modes, and often working in high-demand industries such as aerospace, semiconductor, or automotive can reach or exceed a $500,000 annual salary. Achieving this level typically requires advanced degrees, certifications, and leadership responsibilities, often including bonuses and stock options.
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Failure Analysis Engineer jobs near you
Failure Analysis Engineer, Microelectronics (Starlink)

Failure Analysis Engineer, Microelectronics (Starlink)

SpaceX

Bastrop, TX • On-site

Other

Posted 15 days ago

SpaceX rating

8.7

Company rating: 8.7 out of 10

Based on 144 frontline employees who took The Breakroom Quiz

14th of 60 rated aerospace companies

Job description

SpaceX was founded under the belief that a future where humanity is out exploring the stars is fundamentally more exciting than one where we are not. Today SpaceX is actively developing the technologies to make this possible, with the ultimate goal of enabling human life on Mars.
FAILURE ANALYSIS ENGINEER, MICROELECTRONICS (STARLINK)
Starlink is SpaceX's ambitious goal to bring high-quality internet to the globe by building a constellation of thousands of satellites in low Earth orbit (LEO) using our Falcon 9 and Starship reusable rockets. We are developing millions of devices for end users to link our customers to our satellites.
As a Failure Analysis Engineer on the Starlink team, you will perform detailed root cause failure analysis on microelectronic components and packaging to support high-volume manufacturing, qualification, and field returns. You will leverage advanced laboratory tools and physics-of-failure techniques to identify failure mechanisms and drive corrective actions that improve the reliability of our satellite constellation and user terminals.
RESPONSIBILITIES:
  • Own end-to-end root cause failure analysis investigations on microelectronics failing in manufacturing, test, and field, from initial failure characterization through final corrective action verification
  • Conduct advanced electrical fault isolation and characterization using curve trace, TDR, RF characterization, Lock-in Thermography, OBIRCH, EBIRCH, EBAC, nanoprobing, and related techniques to precisely localize defects in complex devices
  • Perform advanced physical failure analysis using SEM, FIB, EDS, SAM, cross-sectioning, and related techniques to identify failure mechanisms in silicon, packaging, and interconnects
  • Apply physics-of-failure principles and deep knowledge of semiconductor failure modes (electromigration, thermal fatigue, delamination, EOS/ESD, solder joint fatigue, etc.) to determine root causes
  • Drive corrective actions by working directly with silicon design, packaging, and manufacturing teams to implement and validate design or process changes based on FA findings
  • Author detailed technical reports documenting failure modes, root cause conclusions, supporting data, and corrective action effectiveness
  • Develop and improve failure analysis techniques and workflows to support new packaging technologies and advanced materials

BASIC QUALIFICATIONS:
  • Bachelor's degree in materials science, electrical engineering, physics, chemical engineering, or other STEM discipline
  • 2+ years of hands-on experience in microelectronics failure analysis or materials characterization (internship experience is applicable)

PREFERRED SKILLS AND EXPERIENCE:
  • Master's or PhD in materials science, electrical engineering, physics, chemical engineering, or other STEM discipline with a focus on microelectronics or failure analysis
  • Direct experience with failure analysis tools and techniques (SEM, FIB, EDS, cross-sectioning, fault isolation, or equivalent)
  • Strong understanding of semiconductor physics and common microelectronics failure mechanisms (electromigration, thermal fatigue, delamination, solder joint fatigue, electrical overstress/ESD, etc.)
  • Proficiency with advanced FA tools including SEM, FIB, SAM, and EDS
  • Hands-on experience in electrical characterization and fault isolation techniques such as IV curves, RF/VNA measurement, LIT, OBIRCH, EBIRCH, EBAC, nanoprobing, photon emission, or voltage contrast
  • Experience applying JEDEC and AEC reliability test standards and physics-of-failure methodologies to root cause investigations
  • Experience analyzing complex datasets with Python, JMP, or similar tools
  • Excellent problem-solving, communication, and technical writing skills

ADDITIONAL REQUIREMENTS:
  • Ability to work overtime and weekends as needed
  • Ability to work in a cleanroom or ESD-controlled environment when required

ITAR REQUIREMENTS:
    Learn more about the ITAR here.

SpaceX is an Equal Opportunity Employer; employment with SpaceX is governed on the basis of merit, competence and qualifications and will not be influenced in any manner by race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability or any other legally protected status.
Applicants wishing to view a copy of SpaceX's Affirmative Action Plan for veterans and individuals with disabilities, or applicants requiring reasonable accommodation to the application/interview process should reach out to

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