Hardware Reliability Engineer

About You and The Role

As a Mechanical Hardware Reliability Engineer, you will be responsible for defining and delivering the Safety and Reliability attribute of our latest drone-delivery systems. You’ll combine deep knowledge of failure phenomena in electromechanical devices, hands-on experimentation, and statistical modeling to ensure Zipline’s latest drone-delivery platforms survive the most demanding environments on Earth.

Your work will span from early architecture decisions, like where to apply redundancy, fail-operational strategies, and fault tolerance through the definition of accelerated tests, coding reliability models, and verification methods. You’ll uncover risks early, provide data to risk-based decisions, and guide design teams with clear, actionable recommendations. In doing so, you’ll directly shape the long-term reliability and safety of Zipline’s autonomous aircraft and ground infrastructure.

What You'll Do

• Own the reliability strategy for mission-critical mechanical subsystems or entire systems, applying Design-for-Reliability (DfR) and Physics-of-Failure (PoF) principles.
• Translate system reliability targets into design-level requirements, verification plans, and objective pass/fail criteria.
• Lead DFMEA efforts with cross-functional teams to identify early risks and drive mitigation.
• Develop Accelerated Life Testing (ALT) and environmental test campaigns to validate long-term hardware performance.
• Author test plans and procedures with clear, data-driven pass/fail criteria.
• Lead failure analysis and structured root cause investigations, from component to system-level.
• Lead failure analysis and structured root-cause investigations, translating findings into design, manufacturing, or operational actions.
• Sign off on test verification results and assess hardware readiness for flight from a reliability standpoint.
• 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.

What You'll Bring

• B.S. or M.S. in Mechanical Engineering, Materials Engineering, or a related technical discipline.
• Strong mechanical engineering fundamentals and the ability to reason from first principles about hardware behavior and failure.
• Hands-on experience developing and validating safety-critical electromechanical systems through delivery to customers.
• Experience applying reliability methods such as DFMEA, accelerated-life testing, environmental testing, failure analysis, or life modeling.

• 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.

What Else You Need To Know

The starting cash range for this role is $125,000 - $200,000. 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; overtime pay; discretionary annual or performance bonuses; sales incentives; benefits such as medical, dental and vision insurance; paid time off; and more.

Zipline is an equal opportunity employer and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws or our own sensibilities.

We value diversity at Zipline and welcome applications from those who are traditionally underrepresented in tech. If you like the sound of this position but are not sure if you are the perfect fit, please apply!