Reliability Engineer - Marlborough, MA

IPG Photonics is revolutionizing the laser industry as the pioneering developer and leading producer of fiber lasers and amplifiers. Headquartered in Marlborough, MA, IPG has over 4,800 employees in more than 30 locations around the world. We aspire to work together with our employees and customers to apply light in ways that improve life.

Our mission is to develop innovative laser solutions to make the world a better place. To accomplish this mission, we are committed to attracting and retaining the best talent and an engaged and thriving workforce that drives a sustainable future for our company and society.

Working at IPG Photonics you can expect challenging projects, a motivating and friendly environment, and working hand-in-hand with skilled teams of software and hardware engineers.

Job Summary

The Reliability Engineer is responsible for ensuring the long-term performance, robustness, and durability of ultrafast (picosecond/femtosecond) and UV laser systems. This role focuses on reliability modeling, lifetime testing, failure analysis, and continuous improvement of laser modules, nonlinear conversion stages, optical components, electronics, and packaging. The engineer works cross-functionally with R&D, manufacturing, quality, and field service teams to enhance product reliability across the full lifecycle.

• Develop and implement reliability plans for ultrafast and UV laser products.
• Define reliability requirements and qualification criteria based on customer requirements and industry standards.
• Perform reliability allocation and prediction (MTBF, FIT rate analysis).
• Develop reliability growth plans and tracking metrics.

• Design and execute accelerated life tests (ALT, HALT, HASS).
• Conduct environmental testing (thermal cycling, humidity, vibration, shock).
• Develop stress screening procedures for optical, electronic, and optomechanical assemblies.
• Establish degradation monitoring protocols

• Lead root cause analysis (RCA) for field returns and production failures.
• Perform detailed failure analysis on:
  
  
  
  • UV-induced optical degradation
  • Coating damage and contamination
  • Thermal lensing and beam distortion
  • Nonlinear crystal degradation
  • High-voltage electronics failures
  
  
  
  
• Apply structured methodologies (FMEA, 8D, Fishbone, Weibull analysis).
• Work with suppliers to address component-level reliability issues.

• Collaborate with R&D during product development to improve:
  
  
  
  • Thermal management
  • Mechanical stability
  • UV optical lifetime
  • Nonlinear conversion efficiency stability
  
  
  
  
• Conduct FMEA reviews for new designs.
• Recommend material and component upgrades to extend lifetime.

• Analyze field and test data using statistical tools.
• Perform Weibull and life data analysis.
• Build predictive degradation models for UV optics and ultrafast components.
• Maintain reliability databases and dashboards.

• Support field service teams in diagnosing complex failures.
• Analyze warranty trends and customer feedback.
• Provide technical reports on reliability performance.

• Bachelor's or Master's degree in Electrical Engineering, Physics, Optical Engineering, Mechanical Engineering, or related field.
• 3-8+ years of experience in reliability engineering or laser/optical systems.
• Experience with:
  
  
  
  • Ultrafast lasers (ps/fs fiber or solid-state)
  • UV laser systems and frequency conversion stages
  • Optical coatings and nonlinear crystals
  
  
  
  
• Strong understanding of:
  
  
  
  • Laser physics and nonlinear optics
  • Thermal and mechanical stability in precision systems
  • High-power diode reliability
  
  
  
  
• Experience with reliability analysis tools (Weibull, Minitab, JMP, ReliaSoft, etc.).
• Familiarity with HALT/HASS methodologies.
• Strong root cause analysis skills.

Preferred Qualifications

• Experience with industrial laser systems (micromachining, semiconductor, medical).
• Knowledge of UV-induced material degradation mechanisms.
• Understanding of contamination control in UV systems.
• Experience with cleanroom processes.
• Six Sigma or Reliability Engineering certification (CRE).

• Analytical thinking and structured problem solving
• Strong cross-functional communication
• Detail-oriented with systems-level perspective
• Hands-on troubleshooting capability
• Data-driven decision making

• Reduction in field failure rate
• MTBF improvement
• Warranty cost reduction
• Successful product qualification on schedule
• Closure rate and effectiveness of RCAs