Senior/Staff Power Electronics Hardware Reliability Engineer

As a Senior or Staff Power Electronics Hardware Reliability Engineer at Zipline, you will serve as the reliability technical lead for critical high-power electrical systems, initially focusing on drone charging systems that convert AC grid power to low-voltage DC outputs. You will identify dominant lifetime and failure risks in power-conversion hardware, influence architecture and design, and apply Physics-of-Failure, Design-for-Reliability, accelerated testing, and hands-on failure analysis. You will work closely with design, test, systems, manufacturing, supplier quality, and operations teams, providing independent technical leadership and defining best practices for power-electronics reliability engineering at Zipline.

Responsibilities

• Own the reliability strategy for high-voltage power electronics and power-conversion systems, beginning with Zipline’s grid-connected power converters.
• Identify and prioritize the dominant reliability risks for high voltage power electronics, considering electrical, thermal, mechanical, environmental, and operational stresses.
• Lead DFMEA efforts with cross-functional teams to identify early risks and drive mitigation.
• Evaluate power-electronics architectures, schematics, PCB layouts, component selections, packaging concepts, thermal-management approaches, insulation systems, connectors, and high-current interconnects from a reliability perspective.
• Develop physics-based Accelerated Life Testing (ALT) and environmental test campaigns to validate long-term hardware performance.
• Author clear, technically rigorous test plans and specifications, and provide reliability sign-off on test results and hardware readiness.
• Lead failure analysis and structured root cause investigations, from component to system-level.
• Define operational life limits and service intervals using a combination of test data, field returns, and statistical models.
• Advocate cross-functionally for reliability: maintain an appropriately high reliability bar based on risk assessment and stage of program
• Improve Zipline’s reliability methods, tools, standards, and decision-making processes as the company scales.

Requirements

• B.S. or M.S. in Electrical Engineering or a related technical discipline.
• At least 5 years of relevant engineering experience, with 8–10+ years strongly preferred for Staff-level scope.
• A strong electrical engineering foundation and the ability to reason from first principles about hardware behavior and failure.
• Deep experience developing and validating safety-critical high-voltage and high-power electrical systems such as grid-connected converters, industrial power supplies, EV charging systems, inverters, high band gap semiconductors, renewable-energy systems, aerospace power systems, or similar equipment.
• Solid understanding of schematic design and PCB layout for power circuits.
• Strong technical communication skills, including the ability to:
• explain complex technical issues clearly;
• synthesize ambiguous information into a coherent problem statement;
• write concise, decision-oriented technical documentation; and
• drive cross-functional alignment on reliability trade-offs and technical decisions around design, supply-chain, quality, manufacturing, finance, and operations.
• Demonstrated ownership and practical problem-solving ability, including driving technically complex issues through resolution.
• Ability to learn quickly, independently develop new technical depth, and adapt as program needs evolve.

Benefits

• The starting cash range for this role is $140,000-$230,000. Please note that this is a target, starting cash range for a candidate who meets the minimum qualifications for this role. The final cash pay for this role will depend on a variety of factors, including a specific candidate's experience, qualifications, skills, working location, and projected impact. The total compensation package for this role may also include: equity compensation; discretionary annual or performance bonuses; sales incentives; benefits such as medical, dental and vision insurance; paid time off; and more. This position may be hired at one of two levels based on the candidate’s experience, skills, and demonstrated scope:
• Senior Power Electronics Hardware Reliability Engineer: $140,000–$180,000
• Staff Power Electronics Hardware Reliability Engineer: $140,000–$230,000