Senior Hardware Reliability Engineer

Senior Staff Hardware Reliability Engineer

Hybrid – Fremont, CA

About Agility Robotics: Agility Robotics is at the forefront of humanoid robotics, redefining how robots interact with and navigate the human world. Our cutting‑edge robots rely on advanced hardware systems, including actuators, motor controllers, sensors, PCBAs, limbs, and end effectors, to perform complex tasks in dynamic and demanding environments.

Role Overview: We are seeking a Senior Staff Reliability Engineer with 15+ years of experience to join our team in the San Francisco Bay Area. In this hybrid role, you will serve as the technical leader for humanoid robot reliability. This role is critical to ensuring the performance, safety, and durability of our products throughout their lifecycle. Leveraging your deep expertise in reliability engineering, you will lead efforts to establish reliability standards, conduct advanced analyses, and drive improvements across key hardware components and systems.

• Reliability Strategy
  • Lead the overall hardware reliability strategy across the full humanoid robotic system including actuators, motor controllers, PCBAs, sensors, limbs, and end effectors.
  • Define reliability metrics, lifecycle‑stage goals, and test protocols from design through production.
  • Drive Design for Reliability practices (FMEA/DFMEA, stress analysis, reliability growth modeling) and integrate reliability into cross‑functional engineering design workflows.
  • Develop reliability standards and targets, documentation, and best practices to scale future hardware development.
• Reliability Testing & Analysis
  • Develop and execute reliability validation plans including HALT, HASS, vibration, thermal cycling, and environmental stress testing.
  • Design accelerated testing approaches that extract meaningful insights from small sample sizes using statistical methods and engineering judgment.
  • Apply component derating principles and perform thermal, electrical, mechanical, and Coffin‑Manson fatigue analyses to predict lifecycle and identify failure risks.
• Failure Analysis & Continuous Improvement
  • Lead hardware failure RCA efforts, implementing corrective and preventative actions.
  • Analyze prototype, production, and field data to identify trends and drive reliability improvements.
  • Partner with suppliers to ensure sourced components meet reliability and quality standards.
  • Communicate reliability insights to engineering leadership and executives, and mentor junior engineers to build a strong reliability culture.

• Experience:
  • Minimum of 15 years of experience in reliability engineering for complex hardware systems.
  • Strong preference for candidates with experience in robotics, autonomous vehicles, aerospace, or other high‑reliability industries.
• Technical Expertise:
  • Extensive experience with reliability engineering principles, including component derating, FMEA/DFMEA, and Coffin‑Manson analysis for fatigue prediction.
  • Proficiency in reliability testing methods such as HALT, HASS, vibration, and thermal cycling.
  • Strong understanding of mechanical systems, electronic components (PCBAs, motor controllers), sensors, and materials science.
• Skills:
  • Exceptional problem‑solving and analytical skills, with a focus on data‑driven decision‑making.
  • Excellent communication and collaboration abilities, capable of working with cross‑disciplinary teams and suppliers.
  • Proven ability to lead RCA efforts, implement corrective actions, and drive reliability improvements.
  • Experience with industry‑standard reliability engineering and modeling tools such as Relia Soft, ANSYS Sherlock, and Windchill Quality Solutions (Relex).
• Education:
  • Bachelor’s degree in Mechanical Engineering, Electrical Engineering, or a related field (Master’s or PhD preferred).

Location: Hybrid position based out of Fremont, CA office.

Salary: Anticipated Base Salary Range: $213,000 – $277,000 USD.

Benefits:

• 401(k) Plan – Includes a 6% company match.
• Equity – Company stock options.
• Insurance Coverage – 100% company‑paid medical, dental, vision, and short/long‑term disability insurance for employees.
• Benefit Start Date – Eligible for benefits on your first day of employment.
• Well‑Being Support –…