Rooted in Reliability:  Preventing Failures and Building Trust 

At Wolfspeed, innovation isn’t just about what we build — it’s about how we ensure it stands the test of time. That’s where Don Gajewski, Director of Reliability and Failure Analysis, and his team come in.

In a recent conversation as part of our PowerMakers series, Don shared insights into his work, the science behind semiconductor reliability, and the critical role his team plays in keeping Wolfspeed at the forefront of silicon carbide technology.

Engineering Confidence into Every Device

Don leads a specialized team of PhDs and senior engineers focused on two core functions: device reliability and failure analysis. Together, they uncover how and why devices might fail — and more importantly, how to prevent it.

Using advanced tools like electron and acoustic microscopes, Don’s team dives deep into the microscopic world of defects and stresses. Their work helps predict how products will perform over time, ensures new technologies meet rigorous standards, and supports customers in designing for long-term reliability.

“If a customer comes to us and says, ‘Here’s how we’re using your devices,’ we can tell them what to expect in terms of failure rate — and whether they might want to consider a different approach,” Don explains.

When Curiosity Drives Breakthroughs

A standout story from Don’s team highlights the power of persistence and cross-functional collaboration. During routine accelerated life testing, an engineer flagged an unusual result — a lifetime prediction much shorter than expected. What followed was a months-long investigation involving Don’s reliability and failure analysis teams, R&D, and manufacturing.

Eventually, the team discovered microscopic residue of material left behind during wafer processing. It wasn’t visible on the surface but could cause early breakdowns under certain conditions. Once the cause was identified, the team developed and implemented a design fix — preventing future failures and reinforcing Wolfspeed’s commitment to quality.

“We had to escalate it, bring in multiple teams, and really investigate every angle. But in the end, we solved it. That’s what makes this work so rewarding.”

Proactive, Not Reactive

While customer collaboration is a key part of the job, being proactive is also critical. Don’s team conducts proactive reliability testing to simulate real-world conditions — from extreme temperatures to high voltages — tailored to the specific environments customers operate in, whether that’s automotive, industrial, or renewable energy.

Still, when customer feedback does happen, Wolfspeed’s technical experts are ready. In complex cases, they’ll engage directly with the customer’s engineering teams to share findings and co-create solutions.

AI, Defects, and Cross-Functional Collaboration

Wolfspeed’s leadership in silicon carbide goes beyond product design — it’s also in how teams work together. Don now partners closely with colleagues like Matt Conrad, a fellow PowerMaker, whose team is using AI and machine learning to detect wafer defects with greater precision.

This cross-functional approach has been championed by CTO Elif Balkas, who Don credits with creating new bridges between teams that hadn’t traditionally worked side-by-side.

“Since Elif joined, there’s been a lot more collaboration. I work with Matt now on imaging defects — that kind of synergy is making a real impact.”

Silicon Carbide’s Expanding Potential

Don also sees the future in how Wolfspeed’s technology is being applied. Beyond EVs and renewable energy, new frontiers are emerging — like power supplies for AI data centers and modernizing the electrical grid with more efficient, high-voltage solutions.

“Power-hungry AI applications require very efficient power supplies. Silicon carbide makes that possible — and it’s just the beginning.”

What Drives a PowerMaker

Don’s journey to Wolfspeed began with a PhD in physics and a desire to solve real-world problems. More than 25 years later, he’s still in the field of reliability — not because he planned it, but because he found a place where curiosity, complexity, and collaboration meet.

“The technology is fascinating. It’s interdisciplinary, challenging, and I get to work with some of the smartest people I’ve ever met. That’s what keeps me here.”

Why It Matters

Don’s story is a powerful example of what makes Wolfspeed different: technical depth, a passion for problem-solving, and a culture that values collaboration. As silicon carbide technology unlocks the next generation of clean energy and electrification, teams like Don’s are ensuring that every step forward is built on a foundation of trust and reliability.