Reliability Engineer

Position: Reliability Engineer

Location: Etters, PA

RESPONSIBILITIES:

Test, Validation & Qualification

Develop and execute reliability and qualification test plans specific to AI-scale cable assemblies, including: Thermal cycling and thermal aging Temperature/humidity bias (THB) Vibration and mechanical shock Flex, bend, torsion, and pull testing Connector mating/unmating durability Accelerated life testing (ALT) with combined stresses

Failure Analysis & Root Cause

Lead complex electrical-mechanical failure analysis for cable assemblies, including: Intermittent opens and shorts Signal degradation over life Connector fretting, corrosion, or plating wear Crimp, weld, or termination failures.

Apply structured root cause methods (8D, 5-Why, Fishbone) supported by: Electrical probing and TDR X-ray and micro sectioning Optical and SEM analysis (as applicable)

Reliability Modeling & Data Analytics

Build life and reliability models (Weibull, Arrhenius, Coffin-Manson, Miners rule) appropriate for cable and connector failure mechanisms. Correlate accelerated test results with field data to validate models and confidence levels. Analyze FRACAS, RMA, and deployment data to identify systemic risks across large-scale AI infrastructure. Understanding of FIT and MTBF software

Technical Leadership & Documentation

Author reliability reports, qualification summaries, and launch readiness documentation suitable for executive and customer review. Clearly communicate reliability risks and tradeoffs in high-performance AI systems.

QUALIFICATIONS:

Bachelors degree in Electrical Engineering, Mechanical Engineering, or related field

5+ years of experience in reliability engineering, validation, or failure analysis for cable assemblies, connectors, or high-speed interconnects.

Strong understanding of high-speed electrical performance and how it degrades over time and stress.

Hands-on experience with mechanical and environmental testing of cable assemblies.

Proven experience diagnosing intermittent and mixed electrical-mechanical failures.

Proficiency with reliability statistics and life data analysis (Weibull, ALT correlation).

Strong cross-functional communication and technical leadership skills.

Additional Qualifications

Experience with AI data center or hyperscale infrastructure.

Familiarity with high-speed copper and hybrid cable technologies (DAC, AOC, internal high-speed harnesses).

Working knowledge of SI/PI concepts (eye margin, BER, impedance control) as they relate to reliability.

Familiarity with relevant standards (IPC, IEC, Telcordia, MIL-STD, or equivalent).

Ability to travel internationally and domestically, up to 20%.

Key Competencies

Systems-level thinking across electrical, mechanical, and environmental domains

Strong lab-based troubleshooting and root cause analysis

Data-driven decision making under ambiguity.

Ability to balance performance, reliability, cost, and deployment speed.

Clear, concise technical communication