Process Engineer - Pressing; and green cut

Process Engineer - Pressing (and green cut)

Who we are:

We are on a mission to become a leading supplier of critical materials that enable the green energy and technology revolution. Our materials and technologies are required for the electric vehicle, green energy, consumer electronics, and defense industries, and our battery grade lithium and tech metals are needed for chipsets, semiconductors, and 5G.

We have a substantial interest in the Round Top, Heavy Rare Earth, Lithium and Critical Minerals deposit in West Texas. We have also developed the United States’ first rare earth and critical minerals processing facility and we own the only scalable, sintered neo‑magnet manufacturing system in the Western Hemisphere. By developing this fully integrated, US‑based “mine‑to‑magnet” critical mineral supply chain, we are poised to become the leading domestic supplier to these industries.

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, but safety, quality, and excellence always come first.

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.

We are seeking a Process Engineer – Pressing to lead the design, operation, and optimization of all pressing processes within our fast‑growing magnet manufacturing start‑up. This role will oversee operations from jet‑milled powder through pressing, green part handling, and cutting, ensuring process stability, magnetic alignment, and uniform green density. You’ll play a key role in managing recycles and slurry systems while driving consistent product quality and efficient downstream operations in a dynamic, high‑growth production environment.

• Define and maintain slurry preparation and wet pressing parameters to achieve consistent green density and orientation.
• Oversee press setup, tooling design, and magnetic field application during pressing.
• Develop processes for green cutting, trimming, and part separation.
• Establish handling methods to minimize green part damage prior to sintering.
• Manage green recycles and slurry re‑use processes, ensuring quality control.
• Develop and maintain SOPs, FMEAs, and control documentation.
• Analyze press data (force, alignment, density) and drive improvements in yield and process stability.
• Interface with Maintenance and Facilities on press utilities, cooling, and magnetic field systems.
• Collaborate with Furnace Engineer for green part drying, pre‑sintering loading, and tray design.
• Participate in equipment selection and qualification for presses, dryers, and cutting systems. This includes both wet pressing systems and future dry pressing systems that require more protected environmental considerations.

• Bachelor’s degree in Mechanical Engineering, Chemical Engineering, Materials Science, or a related field (advanced degree preferred).
• 3–5 years of experience in pressing, powder handling, or materials processing.
• Proficiency in slurry preparation, wet pressing parameters, green part handling, and tooling/magnetic field setup.
• Strong analytical and problem‑solving skills, including data…