Process Engineer - Powder

Company Overview

MP Materials (NYSE: MP) is rebuilding American industrial capability for a new era of autonomy, robotics, and electrification. We are the only U.S. company with a fully integrated rare earth supply chain—from mining and refining to advanced metal and magnet manufacturing. Our products include critical materials used to make permanent magnets and finished magnets for technologies in robotics, automation, aerospace, transportation, defense, and energy systems.

These materials enable next‑generation technologies and are the foundation of physical AI.

The Process Engineer – Powder joins a team designing and building a greenfield metal, alloy, and magnet‑making facility. The role supports controlling metal powder production processes such as powder conveyance, hydrogen decrepitation, jet milling, classification, blending, and quality control. The engineer will collaborate across chemical, mechanical, and thermal processes, coordinate with technical specialists, and ensure customer requirements are met.

• Member of the Production Engineering team, working with upstream and downstream processes to execute products for customers.
• Collaborate with procurement, vendors, maintenance, operators, and other team members on equipment specification, design reviews, and commissioning of new plant.
• Contribute to EHS risk assessments, HAZOP studies, and regulatory compliance.
• Plan, execute, and assist with process and procedure development for hydrogen decrepitation (HD) furnace, jet milling, dry grinding, and powder blending.
• Work closely with the NPI team on new process development and deployment at industrial scale.
• Provide technical training and support to production team and technicians on process knowledge.
• Evaluate customer requirements and partner with broader manufacturing and engineering teams to define process control plans.
• Monitor and direct changes to key operating parameters to achieve high yield, consistent product quality, and minimal EHS impacts.
• Supervise daily use of quality control procedures, driving initiatives to ensure stable and efficient powder processing operations.
• Investigate and resolve equipment and quality issues within HD furnace, jet milling, and subprocesses, working with QA, production, and customer service.
• Document and disclose intellectual property and assist in patent filing preparation and defense.
• Other duties as assigned.

• BS degree in Metallurgy/Materials Science, Mechanical, Chemical Engineering, Chemistry, or related field.
• 3–5 years’ experience in metal powder processing with industrial‑scale processes and equipment.
• Deep understanding of powder metallurgy processes for part manufacturing and powder quality control fundamentals such as particle size distribution, particle flowability, and agglomeration.
• Knowledge of gathering and tracking process control information for SPC.
• Problem‑solving experience (FMEA, 8D, A3, Root Cause Analysis, etc.).
• Excellent written and verbal communication skills.
• Experienced user of Microsoft Office suite.
• Valid driver’s license and good driving record required to drive company vehicles on property.

• 5+ years of industrial experience in powder manufacturing, processing, and/or conducting powder metallurgy processes.
• Deep technical knowledge of metal powder pulverization and hydrogen furnace operation.
• Practical experience with process safety associated with metal powder processing.
• Experience with SAP.
• Ability to identify and solve problems and to convince others, from management to operators, of the merit of solutions.
• Experience with programming and process control operations: P&, PLC, CFD, MATLAB, Python, Mini‑Tab, AutoCAD/Solid Works.

MP Materials is an Equal Opportunity / affirmative action employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, protected veteran status, or any other characteristic protected by law. Under‑represented groups, women, disabled, and veterans are encouraged to apply. Candidates with disabilities for whom accommodations are needed to perform essential functions of the job will be considered qualified.