Senior Reliability Test Engineer

Position Summary

At FlightWave, we build high-performance Unmanned Aircraft Systems (UAS) for defense, public safety, and other mission-critical applications. We’re looking for a Senior Reliability Test Engineer to lead the development and execution of reliability test plans across our drone platforms — ensuring our systems perform with precision and reliability in the harshest operational environments.

You’ll work hands-on and collaborate across hardware, software, and manufacturing teams to plan and run environmental, mechanical, and lifecycle tests. You’ll apply a systems-level view to validation, spanning electro-mechanical, structural, aerodynamic, and electro-optical interfaces, and help shape how FlightWave designs, tests, and qualifies its autonomous aerial systems.

Location Note: This role is onsite in Carson, California.

Essential Duties and Responsibilities

• Develop and execute system and component-level reliability and design verification test strategies for rugged, airborne electromechanical systems.
• Design and carry out environmental and mechanical stress tests including vibration, shock, thermal cycling, moisture/ingress, and fatigue testing.
• Create custom test fixtures, automation, and data acquisition systems as needed to enable robust, repeatable validation.
• Apply Design of Experiments (DOE), life data analysis, and other statistical techniques (e.g., capability analysis, regression, Weibull analysis) to extract insights and support engineering decisions.
• Partner with supplier quality and purchasing teams to support component qualification, test method validation, and vendor development efforts.
• Contribute to and review risk management deliverables (e.g., DFMEA/PFMEA) and propose test strategies that address top failure modes.
• Support root cause investigations and drive corrective actions through structured test and analysis methods.
• Other duties as assigned.

Required Qualifications

• B.S. in Mechanical Engineering, Aerospace, Electrical, or a related discipline.
• 5 years of experience in reliability, product validation, or mechanical test engineering.
• Hands-on experience designing and building custom test setups, data acquisition systems (image capture, vibration analysis, thermal measurement, EMC/EMI measurement, etc)
• Hands-on experience developing and executing qualification test plans for complex electromechanical systems.
• Demonstrated ability to apply statistical analysis in the context of product testing and reliability evaluation.
• Strong organizational planning skills and enthusiasm to develop high-level validation strategy

Additional Desired Qualifications

• Familiarity with industry-specific environmental test standards (MIL-STD-810, DO-160, etc.) and associated test methods.
• Experience with lightweight aerostructures, vibrations, fatigue analysis, etc.
• Experience with UAS systems, robotics, autonomous vehicles, etc.

Physical Requirements and Working Conditions

• Ability to lift and carry up to 25 pounds.
• Ability to stand, walk, and move between lab, office, and manufacturing environments for extended periods.
• Manual dexterity for handling tools, components, and test equipment.
• Visual and hearing ability to safely conduct and monitor test procedures.
• Ability to wear appropriate personal protective equipment (PPE) when required.
• Comfortable working in environments that may involve vibration, noise, temperature variations, or other test-related conditions.

Background Check

This position will require successfully completing a post-offer background check. Qualified candidates with a criminal history will be considered and are not automatically disqualified, consistent with federal and state law.

EEO and ITAR/EAR Work Authorization Disclosure

Red Cat Holdings provides equal employment opportunities (EEO) to all employees and applicants for employment 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. This position requires direct or indirect access to hardware, software, technology or technical data controlled under the International Traffic in Arms Regulations (ITAR) and the Export Administration Regulations (EAR). Successful candidates for positions subject to ITAR/EAR restrictions must provide proof of U.S. Citizenship or Permanent Residence and must not require sponsorship for export-restricted work authorization.

E-Verify

The company participates E-Verify ensure eligibility for employment and compliance with Right to Work rules.

Compensation: $130-165K plus generous annual equity package and potential bonuses.

Salary : $130,000 - $160,000