Role

Failure Analysis Engineer

Investigates why parts fail using lab methods and recommends design or process fixes.

12 chaptersAbout 3 months15–30 min a day11 skills2 projects
Start this path free →

Chapter 1 is free. No card needed.

Day 1 on the Failure Analysis Engineer path.

What a Failure Analysis Engineer does

Finds the root cause of part and product failures for engineering teams, then recommends fixes to improve safety, quality, and reliability.

  • Diagnose failed parts using visual checks, measurements, and lab tests
  • Plan and run failure investigations, including test setup and sample handling
  • Analyze fracture surfaces, wear, corrosion, and material defects
  • Review design drawings, specs, and manufacturing records to spot risk factors
  • Write clear reports with evidence, root cause, and corrective actions
  • Coordinate with design, manufacturing, and suppliers to implement fixes
  • Build and maintain a failure database to track trends and repeat issues

A day in the life

  1. Review new failure cases, set priorities, and plan tests with the team
  2. Prepare samples, run lab equipment, and capture photos and measurements
  3. Meet with design and manufacturing to align on root cause and next steps
  4. Write reports, update tracking logs, and follow up on corrective actions

Tools you will use

Microscopy: optical microscope, scanning electron microscopeMetrology: calipers, micrometers, coordinate measuringMaterials testing: hardness testing, tensile testingChemistry checks: spectroscopy, contamination testingData tools: Excel, PythonDocumentation: technical reports, issue tracking

Your plan

Chapter by chapter.

1~1 wk

See what failure analysis engineer work involves

StartFree
2~1 wk

Communication and Collaboration

Skills
31–2 wks

Rebuild the root cause of a public product recall

Proof
4~1 wk

Meet people who do failure analysis engineer work

People
5~1 wk

Investigation and Problem Solving

Skills
6~1 wk

Measurement and Lab Practice

Skills
7~1 wk

Risk and Quality Systems

Skills
8~1 wk

Floor Presence and Adaptability

Skills
91–2 wks

Make gage r&r study and measurement procedure for a small part

Proof
10~1 wk

Practise role interviews

Interview
11~1 wk

Choose a route into failure analysis engineer work

Decide
12on your timeline

Apply for roles

Apply

By the last chapter

This is what you can show.

Things you've made

Root-cause failure report and Gage r&r study and measurement procedure for a small part

Skills you can prove

11 skills, each rated on work you actually did.

People you've talked to

3 people who do the job, with a message ready for each.

Questions you can answer

20 interview questions and a mock interview, with feedback.

Credentials

5 credentials compared, so you can pick one, or decide you don't need one. None is required.

Ways in

There is more than one route.

Ways to study

  • Bachelors degree in mechanical engineering, materials science, or metallurgy
  • Bachelors degree in electrical engineering or electronics for electronics failures
  • Technical diploma with lab experience in materials testing or quality inspection
  • Graduate study focused on materials, fracture mechanics, or reliability

How people get their first job

  • Apply for internships in quality, reliability, or test engineering labs
  • Start in manufacturing or quality engineering and take on failure investigations
  • Join a materials testing lab as a technician and build hands-on evidence skills
  • Build a portfolio with lab-style reports from school projects and competitions
  • Earn short courses in root cause analysis and basic statistics

Life skills on this path: Networking · Job interviews · Job search

How the work is changing

What AI is doing to this role

How AI is changing this role · one of 6 tasks we track

Review drawings and manufacturing records for risk

Sped up a lot

What AI does

AI scans records, flags deviations and pulls up change history.

Still yours

Linking a paper deviation to a broken part needs your reasoning.

Reviewed September 2026

In the app · Premium

The rest is in the app

  • How AI affects the other 5 tasks
  • Whether this job is growing or shrinking
  • How hard the first job is to get
  • Similar roles that are easier to get into
  • Updated every month, with sources
See it in the app →

How we rate a job →

Already working

Already a Failure Analysis Engineer?

Plan your move to Senior Failure Analysis Engineer: 9 chapters that end with a strong case for your next review.

Grow in the role →

Other roles in Manufacturing & Quality Engineering

AI Quality Inspection LeadAutomation EngineerCalibration EngineerCommissioning EngineerField Service EngineerIndustrial EngineerMaintenance EngineerManufacturing EngineerManufacturing Test EngineerMaterials Testing EngineerMetrology EngineerNondestructive Testing EngineerPlant EngineerPredictive Maintenance Data EngineerProcess Control EngineerProcess EngineerProduction EngineerQuality Assurance EngineerReliability EngineerSafety EngineerTest EngineerValidation EngineerVerification Engineer

Questions

Questions about this path

How long does it take to become a failure analysis engineer with Welica?

The path is 12 chapters, 3 months at 15 to 30 minutes a day. You can go faster or slower; the plan moves with you.

Do I need a degree?

Not always. Common routes are bachelors degree in mechanical engineering, materials science, or metallurgy, bachelors degree in electrical engineering or electronics for electronics failures, technical diploma with lab experience in materials testing or quality inspection, or graduate study focused on materials, fracture mechanics, or reliability.

What is free?

Chapter 1, See what failure analysis engineer work involves, is free for good. Premium unlocks the rest of the path.

Start the Failure Analysis Engineer path.

Chapter 1 free. About 15 to 30 minutes a day.

Start this path free →

Already have an account? Sign in

Also on iPhone and Android