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Staff Failure Analysis Engineer Jobs (NOW HIRING)

Plexus Corp

Failure Analysis Engineer

Neenah, WI

$63K - $95K/yr

Salary Range: $63,900.00 - $95,900.00 Failure Analysis Engineers are a key resource for the manufacturing team, supporting validation of new processes or material and the identification of issues and ...

Plexus Corp.

Failure Analysis Engineer

Neenah, WI · On-site

$63K - $95K/yr

Salary Range: $63,900.00 - $95,900.00 Failure Analysis Engineers are a key resource for the manufacturing team, supporting validation of new processes or material and the identification of issues and ...

Flex

Failure Analysis Engineer

Memphis, TN · On-site

Typically requires 4 years of experience in test or Failure analysis engineering in the high technology electronics manufacturing industry or companies with data centers and/or providing data center ...

Flex Ltd.

Failure Analysis Engineer

Memphis, TN · On-site

Typically requires 4 years of experience in test or Failure analysis engineering in the high technology electronics manufacturing industry or companies with data centers and/or providing data center ...

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 ...

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Staff Failure Analysis Engineer information

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$23K

$99.3K

$192.5K

How much do staff failure analysis engineer jobs pay per year?

As of Jun 9, 2026, the average yearly pay for staff failure analysis engineer in the United States is $99,330.00, according to ZipRecruiter salary data. Most workers in this role earn between $69,000.00 and $125,000.00 per year, depending on experience, location, and employer.

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

AspectStaff Failure Analysis EngineerFailure Analysis Engineer
CredentialsBachelor's or Master's in Engineering, certifications like ASQ or IPC often preferredBachelor's or Master's in Engineering, similar certifications
Work EnvironmentTypically in R&D or manufacturing settings, leading failure investigationsIn labs or manufacturing facilities, conducting failure analysis tasks
Industry UsageUsed across electronics, automotive, aerospace industriesCommonly found in electronics, semiconductor, and manufacturing sectors

The Staff Failure Analysis Engineer and Failure Analysis Engineer roles share similar educational backgrounds and work environments. The key difference is that the Staff Failure Analysis Engineer often takes on more leadership responsibilities and complex investigations, whereas the Failure Analysis Engineer focuses on executing analysis tasks. Both roles are vital in quality assurance and product reliability across various industries.

How does a Staff Failure Analysis Engineer typically collaborate with other departments to resolve product issues?

As a Staff Failure Analysis Engineer, you will frequently work cross-functionally with design, manufacturing, quality, and reliability engineering teams. Your insights from root-cause investigations are essential for guiding corrective actions and informing design improvements. Effective communication and documentation are key, as you'll often present findings in meetings and generate detailed reports for both technical and non-technical stakeholders. This collaborative environment ensures that product issues are addressed efficiently and future failures are minimized.

What are Staff Failure Analysis Engineers?

Staff Failure Analysis Engineers are specialized professionals who investigate and determine the root causes of product or component failures in manufacturing and engineering environments. They use advanced analytical techniques and tools to identify defects or weaknesses in materials, components, or processes. Their insights help companies improve product reliability, prevent future failures, and support quality assurance. These engineers often work closely with design, manufacturing, and quality teams to implement corrective actions and enhance product performance.

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

To thrive as a Staff Failure Analysis Engineer, you need a solid background in electrical engineering, materials science, or a related field, with expertise in root-cause analysis and semiconductor device physics. Familiarity with analytical tools such as SEM, TEM, FIB, and failure analysis software, as well as industry-standard certifications like IPC or Six Sigma, is often required. Strong problem-solving, attention to detail, and effective communication skills help you collaborate with cross-functional teams and clearly report findings. These skills and qualifications are crucial for diagnosing product failures, improving reliability, and supporting product development cycles.
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What cities are hiring for Staff Failure Analysis Engineer jobs? Cities with the most Staff Failure Analysis Engineer job openings:
What job categories do people searching Staff Failure Analysis Engineer jobs look for? The top searched job categories for Staff Failure Analysis Engineer jobs are:
Staff Failure Analysis Engineer jobs near you
Infographic showing various Staff Failure Analysis Engineer job openings in the United States as of May 2026, with employment types broken down into 100% Full Time. Highlights an 100% In-person job distribution, with an average salary of $99,330 per year, or $47.8 per hour.
Failure Analysis Engineer, Microelectronics (Starlink)

Failure Analysis Engineer, Microelectronics (Starlink)

SpaceX

Bastrop, TX

Other

Posted 1 hour ago

SpaceX rating

8.7

Company rating: 8.7 out of 10

Based on 143 frontline employees who took The Breakroom Quiz

13th 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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