Staff Reliability Engineer

We're looking for a Staff Reliability Engineer for ICON. This role will serve as technical resource on reliability for our fleet of Vulcan and Titan print systems.

This is a high-impact individual contributor role with org-wide reach: you'll diagnose failure patterns others miss, recommend the preventive and predictive maintenance approaches the org should adopt, help shape how root cause investigations get done, and be the technical expert others turn to when the problem is hard.

You’ll be the recognized internal authority on reliability, sitting at the intersection of hardware, data, and operations and you’ll work closely with Sustaining, Field, and Product Engineering to informing how those teams operate and raising their technical quality through your depth and judgment and directly determine how reliably ICON can build at scale.

WHAT YOU’LL DO

• Analyze fleet failure history and field data to identify gaps in the preventive maintenance program for Vulcan and Titan systems, and develop recommendations for schedules, task lists, and compliance tracking that get smarter over time, ensuring Engineering Services sets the standard other teams adopt.

• Identify leading indicators of failure (motor current trends, pressure deviations, vibration signatures), defining condition-based monitoring strategies with the Controls and Software teams.

• Maintain fleet reliability metrics and dashboards in Contour: OEE, uptime, MTBF, MTTR, active print time, keep rates, and downtime attribution, ensuring consistent methodology and calculation logic across teams.

• Continuously evaluate the reliability data available from Vulcan and Titan systems, identifying gaps, defining requirements for new data capture, and coordinating with engineering and software teams to ensure fleet data is structured and accessible for analysis and reporting. Work with ES Leadership to produce FMEA analyses, SOPs, and functional diagrams that serve as durable, org-wide operational resources.

• Serve as a subject matter expert of ICON’s predictive maintenance methodology, suggesting framework iterations to the organization and working with the Director of Engineering Services to implement uses & act on them.

• Perform root cause analysis, develop methodology and templates used across the org; lead or oversee RCAs for significant failures; and ensure findings feed back into PM programs and design teams.

• Lead regular reliability reviews with Sustaining and Product Engineering, presenting fleet trends, RCA findings, and improvement priorities to engineering leadership and driving cross-team alignment on what gets fixed first.

• Develop and maintain test protocols for ECO and upgrade acceptance, defining the criteria and procedures the fleet relies on to validate changes before deployment.

• Validate ECO and upgrade changes in the field before fleet-wide deployment, and assess post-deployment performance, reporting findings back to engineering teams to close the loop.

• Serve as subject matter expert to Field Engineering on troubleshooting and diagnostic standards, providing guidance on procedures, decision trees, and escalation criteria that enable consistent problem resolution across sites.

• Mentor Reliability and Field Engineers across sites on maintenance best practices, translating technical expertise into coaching and resources that raise the quality of practice org-wide. Requirements

• 10+ years of experience in Reliability, Manufacturing, or Quality Engineering, including a track record of defining programs or standards adopted across an organization.

• Bachelor’s degree in Mechanical Engineering, Electrical Engineering, or related field; equivalent experience considered.

• Hands-on experience with complex automated manufacturing or industrial-scale machinery, including sensor systems and associated data.

• Proven experience designing PM and FMEA programs on complex automated equipment that other teams have adopted as standard practice.

• Experience with data pipelining and analytics; able to build reporting systems that drive decisions across teams.

• Demonstrated ability to mentor engineers and set technical direction across functions.

• Strong written and verbal communication skills. This role will lead writing the SOPs field teams rely on and present to engineering leadership regularly. Preferred:

• Experience establishing reliability standards or methodologies in a multi-site or fleet environment.

• Experience with Contour, Palantir Foundry, Spotfire, or equivalent dashboarding platforms.

• Proficiency in Python and/or SQL for pipeline development and analysis.

• Experience with predictive maintenance program design and machine event log analysis.

• Background in construction technology, industrial robotics, or additive manufacturing.

• Advanced degree in a relevant engineering field. WORKING CONDITIONS

• This role works partly on active construction sites and printer test facilities — that means heat, cold, mud, rain, and limited infrastructure on a regular basis. You should be comfortable getting dirty.

• Must be able to lift up to 50 pounds. Some travel required to support field sites and fleet deployments.

ICON is an equal opportunity employer committed to fostering an innovative, inclusive, diverse and discrimination-free work environment. Employment with ICON is based on merit, competence, and qualifications. It is our policy to administer all personnel actions, including recruiting, hiring, training, and promoting employees, without regard to race, color, religion, gender, sexual orientation, gender identity, national origin or ancestry, age, disability, marital status, veteran status, or any other legally protected classification in accordance with applicable federal and state laws. Consistent with the obligations of these laws, ICON will make reasonable accommodations for qualified individuals with disabilities. Furthermore, as a federal government contractor, the Company maintains an affirmative action program which furthers its commitment and complies with recordkeeping and reporting requirements under certain federal civil rights laws and regulations, including Executive Order 11246, Section 503 of the Rehabilitation Act of 1973 (as amended) and the Vietnam Era Veterans' Readjustment Assistance Act of 1974 (as amended).

Headhunters and recruitment agencies may not submit candidates through this application. ICON does not accept unsolicited headhunter and agency submissions for candidates and will not pay fees to any third-party agency without a prior agreement with ICON.

As part of our compliance with these obligations, the Company invites you to voluntarily self-identify as set forth below. Provision of such information is entirely voluntary and a decision to provide or not provide such information will not have any effect on your employment or subject you to any adverse treatment. Any and all information provided will be considered confidential, will be kept separate from your application and/or personnel file, and will only be used in accordance with applicable laws, orders and regulations, including those that require the information to be summarized and reported to the federal government for civil rights enforcement purposes.

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