Principal Hardware Design Engineer – Reliability & Validation

JOB SUMMARY

The Principal Hardware Design Engineer will be responsible for reliability validation and stress testing of advanced electronic instrumentation as part of the Hardware Qualification Assurance program.

This engineer will design, implement, and execute HALT (Highly Accelerated Life Testing) and HASS (Highly Accelerated Stress Screening) programs to ensure that instruments perform reliably under the extreme conditions encountered in the field.

This includes designing and building test apparatus that simulate real-world applications, replicating field failures, and determining root causes through systematic stress testing. The engineer will work closely with Product Architects, Hardware Design Engineers, and Technical Application Engineering to improve robustness and extend product life.
The position reports to the Director of Hardware Engineering and is based in Marlborough, MA.

ESSENTIAL JOB FUNCTIONS

• Design and execute HALT/HASS reliability test plans for electronic instruments deployed in field environments.
• Develop and manage environmental stress test setups (temperature, vibration, voltage/current stress, thermal cycling, etc.) to expose potential design weaknesses.
• Analyze failure modes observed in the field, replicate them under accelerated conditions, and document findings.
• Design test fixtures and calibration systems to support long-term reliability validation.
• Capture and interpret test data, applying statistical and reliability analysis methods (e.g., Weibull analysis, MTBF estimation).
• Generate comprehensive reliability test reports and recommend design or process improvements.
• Collaborate with design and applications teams to ensure hardware robustness before release to manufacturing.
• Provide architectural oversight on reliability test development for new and existing products.
• Participate in system-level testing, integration, and verification of test apparatus.
• Maintain thorough documentation of test procedures, test data, and outcomes for compliance and traceability.

QUALIFICATIONS

Education:

• Bachelor’s Degree in Electrical Engineering or equivalent technical discipline (Master’s preferred).

Required Experience:

• Minimum 10+ years of experience in reliability engineering, HALT/HASS, or environmental stress screening for electronic or power instrumentation systems.
• Proven ability to design and conduct reliability tests and translate field failures into actionable test programs.
• Hands-on experience with environmental chambers, vibration tables, and accelerated life test equipment.
• Strong background in analog/mixed-signal instrumentation, signal measurement, and data acquisition systems.
• Excellent analytical and reporting skills; proficiency in reliability modeling and data visualization tools (MATLAB, Python, LabVIEW, or equivalent).
• Ability to independently plan and execute reliability validation projects with minimal supervision.

Preferred Experience (Not Required):

• Certified Reliability Engineer (CRE) or equivalent Reliability Certification is highly desirable.
• Familiarity with small signal measurements and instrumentation filtering topologies.
• Experience with test automation and data logging.
• Understanding of design-for-reliability (DfR) and field failure analysis.
• Knowledge of schematic capture tools and general hardware test development.

KNOWLEDGE, SKILLS & ABILITIES

• Exceptional communication skills for cross-functional collaboration and reporting.
• Strong analytical and problem-solving skills, with attention to technical detail.
• Ability to present findings clearly to peers, management, and customers.
• Highly organized with the ability to manage multiple test programs simultaneously.

PHYSICAL REQUIREMENTS

While performing the duties of this job, the employee is often required to stand, sit, use computers, read, write, type, use copy machines, file paperwork, use telephones, and communicate effectively.
Must be capable of lifting 30 pounds; assistance is required when lifting 50 pounds or more.

COMPENSATION

Salary Range: $137,042 – $171,303 (commensurate with experience, education, and skill level).

EQUAL OPPORTUNITY EMPLOYER STATEMENT

We are an Equal Employment Opportunity employer that values diversity and inclusion. All qualified applicants, regardless of race, color, religion, gender, sexual orientation, marital status, gender identity or expression, national origin, genetics, age, disability, or veteran status, are strongly encouraged to apply.