Senior Reliability Test Engineer

At FlightWave, we build high-performance Unmanned Aircraft Systems (UAS) for defense, public safety, and other mission-critical applications. We’re looking for a Senior Reliability Test Engineer to lead the development and execution of reliability test plans across our drone platforms — ensuring our systems perform with precision and reliability in the harshest operational environments.

You’ll work hands-on and collaborate across hardware, software, and manufacturing teams to plan and run environmental, mechanical, and lifecycle tests. You’ll apply a systems-level view to validation, spanning electro-mechanical, structural, aerodynamic, and electro-optical interfaces, and help shape how FlightWave designs, tests, and qualifies its autonomous aerial systems.

Location Note: This role is onsite in Carson, California.

Key Responsibilities

• Develop and execute system and component-level reliability and design verification test strategies for rugged, airborne electromechanical systems.
• Design and carry out environmental and mechanical stress tests including vibration, shock, thermal cycling, moisture/ingress, and fatigue testing.
• Create custom test fixtures, automation, and data acquisition systems as needed to enable robust, repeatable validation.
• Apply Design of Experiments (DOE), life data analysis, and other statistical techniques (e.g., capability analysis, regression, Weibull analysis) to extract insights and support engineering decisions.
• Partner with supplier quality and purchasing teams to support component qualification, test method validation, and vendor development efforts.
• Contribute to and review risk management deliverables (e.g., DFMEA/PFMEA) and propose test strategies that address top failure modes.
• Support root cause investigations and drive corrective actions through structured test and analysis methods.
• Other duties as assigned.

Required Qualifications

• B.S. in Mechanical Engineering, Aerospace, Electrical, or a related discipline.
• 5+ years of experience in reliability, product validation, or mechanical test engineering.
• Hands-on experience designing and building custom test setups, data acquisition systems (image capture, vibration analysis, thermal measurement, EMC/EMI measurement, etc)
• Hands-on experience developing and executing qualification test plans for complex electromechanical systems.
• Demonstrated ability to apply statistical analysis in the context of product testing and reliability evaluation.
• Strong organizational planning skills and enthusiasm to develop high-level validation strategy

Preferred Qualifications

• Familiarity with industry-specific environmental test standards (MIL-STD-810, DO-160, etc.) and associated test methods.
• Experience with lightweight aerostructures, vibrations, fatigue analysis, etc.
• Experience with UAS systems, robotics, autonomous vehicles, etc.

Physical Requirements

• Ability to lift and carry up to 50 pounds.
• Ability to stand, walk, and move between lab, office, and manufacturing environments for extended periods.
• Manual dexterity for handling tools, components, and test equipment.