Job Description
Job Description
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, Miner’s 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:
- Bachelor’s 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).
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