Failure Analysis Engineer

cai; Virginia (MN); On-site; USD 85,000 - 120,000; Full time

Job summary

CAI is seeking a Failure Analysis Engineer to join the Failure Analysis and Engineering team in Hampton, VA. This full-time on-site role focuses on investigating product failures, manufacturing issues, customer complaints, and field returns, applying materials engineering expertise and hands-on analysis.

The candidate will perform destructive and non-destructive analyses, generate detailed reports, and support root-cause investigations using structured methodologies.

Qualifications

• B.S. degree in materials/engineering or related field.
• 3–5 years of experience in failure analysis or related discipline.
• Hands-on root cause investigations and failure analysis activities.
• Knowledge of microscopy, SEM/EDS, X-ray, FTIR, DSC or related methods.
• Strong problem-solving and technical reporting skills.

Responsibilities

• Perform failure analysis on returns, defects, reliability issues and field failures.
• Conduct non-destructive and destructive analyses to identify failure modes.
• Generate clear technical reports documenting observations, conclusions, and recommendations.
• Support root cause investigations using 8D, 5 Why, Fishbone, and FTA methods.
• Collaborate with engineering, quality and manufacturing teams to resolve issues.
• Maintain records and ensure compliance with quality systems.

Skills

Failure analysis

Root cause investigations

Materials engineering

Engineering problem solving

Customer complaint investigations

Cross-functional collaboration

Education

B.S. degree in Materials/Mechanical/Electrical/Physics/Chemistry or related field

Tools

SEM/EDS

X-ray inspection

Microscopy

FTIR

DSC

Metallography

Job description

Failure Analysis Engineer

Req number:R8486

Employment type:Full time

Worksite flexibility:Onsite

Who we are

CAI is a global services firm with over 9,000 associates worldwide and a yearly revenue of $1.3 billion+. We have over 40 years of excellence in uniting talent and technology to power the possible for our clients, colleagues, and communities. As a privately held company, we have the freedom and focus to do what is right-whatever it takes. Our tailor-made solutions create lasting results across the public and commercial sectors, and we are trailblazers in bringing neurodiversity to the enterprise.

Job Summary

We are looking for a motivated Failure Analysis Engineer ready to take us to the next level! If you have materials engineering expertise, hands-on failure analysis experience, and strong problem-solving skills, and are looking for your next career move,

Job Description

We are looking for a Failure Analysis Engineer to be a crucial member of the Failure Analysis and Engineering team responsible for investigating product failures, manufacturing issues, customer complaints, and field returns. This position will be Full-Time and On-Site in Hampton, VA.

Export Control Requirement

This position involves access to information and hardware subject to the International Traffic in Arms Regulations (ITAR) and/or Export Administration Regulations (EAR). Candidates must be a U.S. Person as defined by ITAR (U.S. citizen, U.S. permanent resident, or protected individual).

What You'll Do

• Perform failure analysis on customer returns, warranty claims, manufacturing defects, reliability failures, and field returns
• Conduct non-destructive and destructive analysis to determine failure modes and mechanisms
• Utilize analytical techniques, including microscopy, cross-section analysis, material characterization, X-ray inspection, and SEM/EDS
• Prepare samples and perform laboratory investigations according to established procedures and best practices
• Generate clear and concise technical reports documenting observations, findings, conclusions, and recommendations
• Support root cause investigations using structured methodologies such as 8D, 5 Why, Fishbone, Fault Tree Analysis (FTA), and/or Red X
• Collaborate with Product Engineering, Manufacturing Engineering, Quality Engineering, and Operations teams to resolve complex technical issues
• Participate in customer complaint investigations and provide technical evidence supporting corrective and preventive actions
• Support manufacturing sites in resolving scrap, yield, process, and field reliability issues
• Analyze trends in failure data and identify recurring failure mechanisms or systemic issues
• Contribute to product reliability improvements through understanding failure mechanisms and risk reduction recommendations
• Support DFMEA, PFMEA, and Lessons Learned activities through technical findings
• Maintain records, analysis reports, and documentation in compliance with applicable quality management system requirements
• Participate in continuous improvement initiatives focused on quality, reliability, cost reduction, and customer satisfaction
• Work effectively in a cross-functional and global environment supporting multiple manufacturing sites and business units

What You'll Need

Required:

• B.S. degree in Materials Engineering, Mechanical Engineering, Electrical Engineering, Physics, Chemistry, or related technical field
• Minimum 3-5 years of experience in Failure Analysis, Materials Engineering, Reliability Engineering, Product Engineering, Quality Engineering, or related technical discipline
• Hands-on experience performing root cause investigations and failure analysis activities
• Knowledge of analytical and laboratory techniques such as microscopy, metallography, cross-sectioning, SEM/EDS, X-ray, FTIR, DSC, or related methods
• Strong understanding of engineering problem-solving methodologies including 8D, 5 Why, Fishbone, and Fault Tree Analysis
• Experience supporting customer complaint investigations and corrective action activities
• Ability to interpret technical drawings, specifications, product requirements, and engineering documentation

Preferred:

• Knowledge of quality systems and standards such as ISO 9001, IATF 16949, ISO 13485, or AS9100
• Experience using statistical software and analysis tools such as Minitab
• Six Sigma Green Belt, Red X, or equivalent problem-solving certification
• Excellent technical report writing and communication skills
• Ability to independently manage multiple investigations and prioritize activities

Physical Demands

Ability to safely and successfully perform the essential job functions consistent with the ADA and other federal, state, and local standards.

Ability to conduct repetitive tasks on a computer, utilizing a mouse, keyboard, and monitor.

Must be able to communicate with customers and team members over the phone and in person.

Sedentary work that involves sitting or remaining stationary most of the time, with oc