Reliability & Failure Analysis Engineer

About Sesame

Sesame believes in a future where computers are lifelike - with the ability to see, hear, and collaborate with us in ways that feel natural and human. With this vision, we're designing a new kind of computer, focused on making voice agents part of our daily lives. Our team brings together founders from Oculus and Ubiquity6, alongside proven leaders from Meta, Google, and Apple, with deep expertise spanning hardware and software. Join us in shaping a future where computers truly come alive.

As a Reliability and FA Engineer at Sesame, you will be responsible for ensuring the quality, robustness, and longevity of our consumer products. You will define and execute comprehensive reliability test plans, conduct deep-dive failure analysis (FA) on units from testing and field returns, and drive root cause identification and corrective actions. This role requires a strong technical leader who can bridge the gap between design validation and mass production, partnering with cross-functional teams to influence design for reliability (DFR) and ensure our products meet rigorous performance standards.

• Define and execute reliability test plans, including Highly Accelerated Life Testing (HALT), Accelerated Life Testing (ALT), and environmental stress testing.

• Conduct comprehensive failure analysis (FA) on failed units from development, production, and field returns, using advanced analytical techniques and equipment.

• Drive root cause analysis (RCA) and collaborate with cross-functional engineering teams (Mechanical, Electrical, Firmware) to implement effective corrective and preventive actions (CAPA).

• Influence product architecture and design by implementing Design for Reliability (DFR) principles during early development phases.

• Manage reliability lab operations, including equipment maintenance, calibration, and safety protocols.

• Partner with internal and external teams to standardize reliability testing methodologies and validation criteria.

• Support product lifecycle management, from early prototype evaluation through mass production and beyond.

• Develop and maintain technical reports, reliability dashboards, and documentation on product performance trends.

• Bachelor’s degree in Electrical Engineering, Mechanical Engineering, Materials Science, or a related technical field.

• 7+ years of relevant experience in reliability engineering or failure analysis within the consumer electronics industry.

• Hands-on experience with failure analysis tools and techniques, such as X-ray, cross-sectioning, SEM, or optical microscopy.

• Deep understanding of industry-standard reliability testing methodologies and environmental standards.

• Strong problem-solving, communication, and interpersonal skills, with the ability to articulate complex technical findings to diverse teams.

• 10+ years of experience in consumer electronics, with a focus on reliability and failure analysis.

• Master’s degree or PhD in Engineering or a related field.

• Proven experience with wearable devices or small form factor, high-density products.

• Experience with statistical analysis software (e.g., JMP, Minitab) and data-driven reliability modeling (e.g., Weibull analysis).

• Demonstrated success in influencing design decisions to improve product robustness and yield.

Sesame is committed to a workplace where everyone feels valued, respected, and empowered. We welcome all qualified applicants, embracing diversity in race, gender, identity, orientation, ability, and more. We provide reasonable accommodations for applicants with disabilities. Contact [email protected] for assistance.

Full-time Employee Benefits: 

• 401 (k) max employer match: 3.5% of compensation

• 100% employer-paid health, vision, and dental benefits for you and your dependents

• Unlimited PTO and sick time

• Flexible spending account with employer matching up to $1,650/year (medical FSA)

• Guardian Employee Assistance Program (EAP)

• Opportunity to share in the company's success with competitive stock options

Benefits do not apply to contingent/contract workers.