Process Engineer - Micro​/Macro Machining

Process Engineer - Micro/Macro Machining

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

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.

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.

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.

• 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
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  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,…