Process Engineer - Pressing; and green cut

Overview

USA Rare Earth is 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 developed the United States’ first rare earth and critical minerals processing facility and 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:
  We are creative and solution-oriented, and we work across sectors and with customers to deliver world-class solutions in sustainable ways.
• Deliver Quality:
  We uphold high quality standards and balance fast execution with safety, quality, and excellence.
• Lead Responsibly:
  We prioritize safety, accountability, sustainability, and the financial best interests of investors and consumers.
• Win Together:
  We collaborate as a team to establish a rare earth magnet supply chain and continuously learn and improve.

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 oversees operations from jet-milled powder through pressing, green part handling, and cutting, ensuring process stability, magnetic alignment, and uniform green density. You will manage 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 reuse 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, including both wet and future dry pressing systems with 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 analysis and statistical process control (SPC).
• Knowledge of SOPs, FMEAs, and quality control for pressing operations.
• Ability to collaborate effectively with cross-functional teams in a fast-paced, start-up environment.
• Experience managing recycles, slurry reuse, and optimizing process stability and yield.

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. Specific vision abilities required include close and distance vision. The role may require walking, standing, bending, kneeling, reaching, lifting (up to 20 pounds), and other…