Michael Leveille, PhD

Failure Analysis & Reliability Engineer | I design targeted stress tests and multi-modal characterization to isolate mechanisms fast and drive corrective actions that reduce risk.

San Francisco Bay Area

About

Hardware teams don’t lose time because they lack effort. They lose time because failures are hard to reproduce, root cause is unclear, and decisions get stuck in “we need more testing.” That loop creates repeat failures, delayed releases, and warranty or safety risk that shows up when it’s most expensive to fix. I work on the part of the problem that decides whether teams move forward with confidence: turning messy symptoms into a verified failure mechanism and a practical corrective action. I’m a PhD-trained materials scientist with 7+ years of hands-on lab experience across national labs and applied R&D environments. My work has focused on failure-relevant behavior in polymers, thin films, and electrochemical systems, using controlled experiments and multi-modal characterization to explain what changed, why it changed, and what to do next. Here’s what I consistently bring to failure analysis and reliability work: 1) Failure mechanism investigation (RCA + evidence discipline) I approach problems like an investigation, not a guess. I define the failure signature, build hypotheses that can be tested, and use structured root-cause methods to separate noise from signal. 2) Reliability test method development (stress, exposure, reproducibility) I design experiments that reproduce failures under controlled conditions. That includes thermal and mechanical testing, environmental exposure (gas, humidity, solvent), and custom setups when standard methods don’t capture the real scenario. 3) Materials characterization + data analysis (multi-modal + Python/JMP) I use techniques like Raman, FTIR, X-ray methods, microscopy, and thermal/mechanical characterization to link structure and properties to degradation. I back conclusions with clean analysis workflows in Python/JMP so results are traceable and repeatable. I care about meaningful technical impact, hands-on lab work, and reliability outcomes that actually change what gets built, tested, and released. I also value teams that protect focus time and work with clear boundaries. If you work in failure analysis, reliability engineering, sustaining engineering, or hardware validation, I’m always open to connecting. If your team is dealing with repeat failures, slow root-cause cycles, or test results that don’t translate into decisions, feel free to reach out and connect.

Experience