Process Engineering – Macro Machining

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:

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.

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.

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.

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.

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.

• 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…