Staff Hardware Reliability Engineer - Sensors

Who we are Aurora’s mission is to deliver the benefits of self-driving technology safely, quickly, and broadly. The Aurora Driver will create a new era in mobility and logistics, one that will bring a safer, more efficient, and more accessible future to everyone. At Aurora, you will tackle massively complex problems alongside other passionate, intelligent individuals, growing as an expert while expanding your knowledge. For the latest news from Aurora, visit aurora.tech or follow us on LinkedIn . What we are looking for Aurora hires talented people with diverse backgrounds who are ready to help build a transportation ecosystem that will make our roads safer, get crucial goods where they need to go, and make mobility more efficient and accessible for all. We’re searching for a Staff Hardware Reliability Engineer who will join the Hardware Reliability team to ensure the robustness of the Aurora Driver by leading reliability efforts for our next-generation sensor systems (Lidar, Camera, Radar, IMU). This is a high-impact opportunity to work at the forefront of autonomous vehicle technology, collaborating with world-class partners like Volvo, PACCAR, and Aumovio (formerly Continental) to bring a robust, scaled product to market. In this role you will Lead Sensor Reliability Assessments: Conduct rigorous reliability evaluations and design test campaigns for both internal and external sensor designs to ensure they meet our rigorous automotive standards. Drive Failure Analysis (FA): Take ownership of complex reliability failures, and shepherd corrective actions in the form of near term mitigations and longer term design or process fixes. Facilitate Proactive Risk Mitigation: Lead Design Failure Mode and Effect Analysis (DFMEA) sessions and implement corrective action plans based on prior experience and testing. Develop Predictive Reliability Models: Create models to predict failure rates for integrated modules and individual sensors across diverse climates and road conditions. Collaborate Cross-Functionally: Work with Hardware Design, Systems Engineering, Hardware Safety, Field Operations, Emedded Software, and contract manufacturers to integrate reliability findings into the design and manufacturing processes. Required qualifications Extensive Experience in Sensor Validation: Proven track record in developing and validating optomechanical products, including cameras, lidars, or other optical instruments. Expertise in Physics of Failure: Deep understanding of the physics of failure for electronic and optoelectronic components as applied to sensor systems. Reliability Test Design: Strong ability to design and execute reliability test flows (shock, vibration, thermal) suitable for contract manufacturing environments. Technical Data Analysis: Proficiency in analyzing sensor performance data to generate actionable insights. Mass Production Background: Direct experience improving the reliability of mass-produced optomechanical assemblies and managing feedback loops with external vendors. Desirable qualifications Industry Experience: Prior experience at leading R&D at automotive companies Standards Knowledge: Familiarity with AEC-Q, ISO-16750, and other relevant automotive reliability standards. Manufacturing Experience: Experience evaluating the reliability of manufacturing and assembly processes as a product moves toward large-scale production. Hardware-Firmware Interaction: Working knowledge of the interactions between hardware and firmware critical to sensor performance. Breadth of Technical Skills: Conceptual understanding of material science, PCBAs (BGA structural integrity), and conformal coating impacts on humidity exposure. The base salary range for this position is $181,000 - $262,000 per year. Aurora’s pay ranges are determined by role, level, and location. Within the range, the successful candidate’s starting base pay will be determined based on factors including job-related skills, experience, qualifications, relevant educatio