Process Engineer - Micro Machining

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.

What You Can Expect
At USA Rare Earth, we are pioneers and problem solvers, technologists and team players. Together we:
Build Solutions
:
Creative, solution‑oriented, and outside‑the‑box thinking to solve important problems.
Deliver Quality
:
Top‑tier quality leads to industry competitiveness; safety, quality, and excellence come first.
Lead Responsibly
:
Responsibility to the planet, consumers, country, and each other; safety at the center; sustainable practices.
Win Together
:
Communication, teamwork, and continuous improvement to achieve goals.

Lead design, operation, and optimization of all micro‑machining processes within our fast‑growing magnet manufacturing start‑up. Oversee high‑volume precision material slicing, component shaping, and finishing operations to ensure tight tolerances, surface quality, and process stability in a dynamic, high‑growth production environment.

• Own operation and design of micro machining equipment and processes.
• Ensure small parts meet strict dimensional, surface finish, and edge preparation requirements.
• Implement and maintain automation systems to maximize throughput and minimize handling.
• Oversee pre‑inspection cleaning, tumbling, slicing, grinding, and chamfering.
• Maintain SOPs, process documentation, and FMEAs for micro machining.
• Collaborate with maintenance for preventive maintenance and troubleshooting.
• Monitor quality metrics and SPC data to ensure process control.
• Participate in equipment procurement, FAT/SAT, and vendor evaluation.
• Train operators and junior engineers in precision machining, inspection, and safety protocols.
• Interface with downstream coating engineers to ensure parts are ready for plating.

• Bachelor’s degree in Mechanical Engineering, Chemical Engineering, Materials Science, or a related field (advanced degree preferred).
• Experience in micro‑machining, precision part manufacturing, or related processes.
• Strong analytical and problem‑solving skills, including data analysis and SPC.
• Proficiency in operating and optimizing micro‑machining equipment and processes, emphasis on diamond abrasive slicing and grinding for shaping.
• Knowledge of dimensional tolerances, surface finish, and precision inspection.
• Familiarity with SOPs, process documentation, FMEAs, and quality control.
• Ability to collaborate effectively with cross‑functional teams in a fast‑paced start‑up environment.
• Experience with automation, part handling, and training operators or junior engineers is a plus.

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 vision and distance vision. The employee is regularly required to walk, stand, move, sit, carry, bend, kneel, reach, push, pull, lift, use hands and fingers, handle, feel and talk and hear.

May be required to lift and move boxes or packages not exceeding 20 pounds. Some work stress and extended hours may be required.

The work environment will be a mix of a typical office environment, laboratory space, manufacturing floor and construction site.

Exposure will vary and include normal office noise, typical laboratory sounds, manufacturing floor noise, and construction site noise depending on project phase and location.

USA Rare Earth proudly supports Equal Employment Opportunities. USA Rare Earth's policy is to provide equal employment opportunities to all applicants and will provide reasonable accommodations according to applicable federal, state, and/or local laws. For assistance applying for employment through this site due to disability, please contact Human Resources,  to discuss reasonable accommodations.