Job Description

Job Description

Process Engineer - Two openings (Micro Machining and Macro Machining)

Who we are:

We are on a mission to become the leading Western supplier of high value rare earth magnets and critical minerals through a supply chain that supports the future state of energy, mobility, and national security. Our dynamic solution solves key domestic rare earth production challenges through optimizing margins, enhancing efficiency, minimizing costs and mitigating technical challenges.

Our early mover advantage positions us to become the first vertically integrated ex-China rare earth supply chain through substantial interest in the Round Top heavy rare earth, lithium and critical minerals deposit in West Texas, a rare earth separation facility with proven extraction methods, and development of the United States’ first rare earth and critical minerals production facility, with scalable production capability. By developing this fully integrated, US-based “mine-to-magnet” critical mineral supply chain, we are poised to become the leading Western supplier.

What you can expect:

At USA Rare Earth, we are pioneers and problem solvers, technologists and team players. Together, we:

Build Solutions : If our task was a simple one, it would already be done. We are creative and solution-oriented, and we think outside the box to solve important problems. We know that a range of expertise and technologies is needed for success, and we work across sectors and alongside customers to deliver world-class solutions in sustainable ways.

Deliver Quality : When we do things, we do them well. We believe that top-tier quality leads to industry competitiveness and we hold ourselves to the highest quality standards. We move fast when executing, while keeping safety, quality and excellence at the forefront in everything we do.

Lead responsibly : We have a responsibility to the planet, our consumers, our country, and each other. We put safety at the center of all we do, take accountability for our actions, incorporate sustainable practices in our processes and act with the financial best interest of our investors and consumers in mind.

Win Together : Establishing a rare earth magnet supply chain is a big undertaking – and getting there is a team effort. We communicate openly, work together and challenge each other in pursuit of our goals. With every step we take we learn and get better.

Job Summary: Micro Machining

Position Overview: The Process Engineer – Micro Machining is responsible for developing, optimizing, and sustaining fine-tolerance machining processes used to shape and finish magnets or specialty materials. This role ensures dimensional precision, surface quality, and throughput by managing cutting parameters, tooling, fixturing, and process controls. The engineer supports day-to-day production, new product introduction, and continuous improvement in micro-scale machining operations.

Key Responsibilities:

• Micro-Machining Process Development & Optimization - Develop and refine milling, grinding, EDM, laser, or diamond-cutting processes for small or fragile magnet components. Establish machining parameters (speed, feed, depth of cut, coolant flow, tool paths). Optimize for accuracy, surface finish, and minimal chipping/cracking.
• Tooling & Fixturing Design - Specify micro-cutting tools, abrasives, wheels, or nozzles. Design fixtures, soft jaws, or vacuum holding methods for small or brittle parts. Ensure repeatability and precision for high-volume operations.
• Process Monitoring & Control - Maintain SPC for critical dimensions, flatness, rough surface, and tolerances. Track tool wear and establish tool-change intervals. Monitor vibration, coolant conditions, and machine stability.
• Troubleshooting & Root-Cause Analysis - Address issues such as chipping, cracking, breakage, taper errors, burn marks, or uneven surfaces. Use structured problem-solving (5 Why’s, DOE, Fishbone) to drive corrective actions.
• Equipment Support & Upgrades - Work with maintenance on micro-machining centers, precision grinders, EDM/laser systems, and measurement tools. Support calibration, alignment, and preventative-maintenance routines. Evaluate and validate new equipment or cutting technologies.
• Material Characterization & Handling - Understand magnetic material behavior, brittleness, coating sensitivity, and microstructural effects during machining. Define proper handling, washing, and drying procedures to protect part surfaces.
• Quality Assurance - Work with Quality on inspection methods using microscopes, CMMs, laser-gauging, and optical metrology. Define sampling plans and acceptance criteria for fine tolerances.
• Documentation & Standards - Create/update SOPs, process flow diagrams, PFMEAs, and control plans. Maintain machining recipes, tool libraries, and change histories.
• New Product Introduction (NPI) - Support prototype machining, characterization, and capability studies. Establish production-ready machining parameters for new part geometries or materials.
• Safety & Continuous Improvement. Enforce safety practices around fine particulate, coolants, lasers, and precision machinery. Lead projects to increase throughput, reduce scrap, improve tool life, or tighten tolerances.

Knowledge/Skills:

• Experience machining brittle materials (ceramics, magnets, glass, ferrites, hard alloys).
• Familiarity with precision metrology (CMM, optical, laser).
• Knowledge of lean manufacturing and ISO9001/IATF16949.ge, Skills & Abilities:

Minimum Requirements:

• Bachelor’s degree in mechanical engineering, Manufacturing Engineering, Materials Science, or similar.
• 2–5+ years’ experience in machining, micro-machining, precision grinding, or EDM/laser processing.
• Strong understanding of GD&T, precision tolerances, and tool/material interactions.
• Experience with root-cause analysis and SPC.

Job Summary: Macro Machining

Position Overview : The Process Engineer – Macro Machining is responsible for developing, optimizing, and sustaining machining processes used to shape and size larger magnet components or assemblies. This role ensures dimensional accuracy, throughput, and surface quality by managing cutting parameters, tooling, fixturing, and process controls. Engineer supports production operations, leads troubleshooting, and drives continuous improvement across machining centers and related equipment.

Key Responsibilities:

• Machining Process Development & Optimization - Develop and refine milling, turning, grinding, or sawing processes for larger magnet parts. Establish machining parameters (speed, feed, depth of cut, coolant flow, tool paths) for robust, repeatable performance. Optimize for dimensional accuracy, surface finish, and minimal chipping or cracking in brittle materials.
• Tooling & Fixturing Development - Specify cutting tools, wheels, inserts, and fixtures suitable for magnet or special-material machining. Design or improve holding systems (clamps, jigs, soft jaws, magnetic/vacuum fixtures). Improve changeover efficiency and reduce setup variability.
• Process Monitoring & Control - Maintain SPC on critical dimensions, flatness, concentricity, and tolerances. Track tool life, vibration, coolant condition, and machine performance. Ensure consistent machining performance across shifts and machines.
• Troubleshooting & Root-Cause Analysis - Resolve issues such as poor surface finish, out-of-tolerance dimensions, chipping, breakage, or excessive tool wear. Use structured problem-solving methods (DOE, 5 Why’s, Fishbone) to implement corrective actions.
• Equipment & Maintenance Support - Work with maintenance on machining centers, grinders, saws, and material-handling equipment. Support calibrations, alignment checks, PM routines, and machine restorations. Evaluate upgrades or new machining equipment for capability and capacity.
• Material Handling & Protection - Define proper handling, staging, and transportation of larger magnet components to prevent damage. Ensure alignment with downstream processes such as grinding, coating, or assembly.
• Quality Assurance Collaboration - Define measurement methods using calipers, micrometers, bore gauges, CMMs, or optical systems. Establish sampling plans and acceptance criteria for key dimensions and surface characteristics. Support failure analysis for machining-related defects.
• Documentation & Standards - Create/update SOPs, machining recipes, control plans, PFMEAs, and process flow diagrams. Maintain tooling libraries, fixture drawings, and process change records.
• New Product Introduction (NPI) - Support prototype machining, capability studies, and development of machining standards for new magnet designs. Transition successful trials to full-scale production.
• Safety & Continuous Improvement - Ensure safe operation of machining equipment, including coolant handling, chip control, and lifting operations. Lead improvement projects focused on cycle-time reduction, scrap reduction, and tool-life extension.

Knowledge, Skills & Abilities:

• Experience with machining brittle or hard materials (magnets, ceramics, sintered metals).
• Familiarity with CNC machining centers, grinders, and precision metrology.
• Knowledge of lean manufacturing and ISO9001/IATF16949.

Minimum Requirements:

• Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, or related field.
• 2–5+ years of machining or manufacturing engineering experience.
• Strong understanding of machining fundamentals, GD&T, and tooling interactions.
• Experience with SPC and structured problem-solving.

Physical Demands

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

Work Environment:

The work environment will be an office environment. Noise level: Normal office noises

USA Rare Earth proudly supports Equal Employment Opportunities

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