Process Engineer - Milling

Overview

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 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.

What You Can Expect At USA Rare Earth, we are pioneers and problem solvers, technologists and team players. We build solutions, deliver quality, lead responsibly, and win together by collaborating across sectors, staying safety- and quality-first, and delivering sustainable progress.

• Develop and maintain process parameters for tumble and jet mills to achieve target particle size distribution, morphology, and flowability.
• Monitor oxygen, moisture, and contamination levels throughout powder handling and storage.
• Collaborate with R&D and quality on powder characterization, sampling, and analysis methods.
• Specify and maintain equipment for air classification, dust collection, and loading systems.
• Conduct PFMEA and establish control plans for powder processes; maintain documentation.
• Lead continuous improvement initiatives to reduce contamination risk and enhance powder yield.
• Support automation or containment improvements for dust management and operator safety.
• Collaborate with Pressing Engineer to ensure powder rheology and moisture content support stable pressing operations.
• Assist with equipment vendor selection, FAT/SAT, and installation of new mills and classifiers.
• Work with other groups to support the optimization of material handling methods between strip casting, milling, and slurry preparation.

• Bachelor’s degree in Chemical Engineering, Materials Science, Mechanical Engineering, or a related field (advanced degree preferred).
• 3–5 years of experience in milling, powder metallurgy, or materials processing within a manufacturing environment.
• Proficiency in process modeling, data analysis, and statistical process control (SPC).
• Strong problem-solving and troubleshooting skills related to particle quality and process efficiency.
• Knowledge of safety, quality, and industry standards for powder and materials processing.
• Ability to collaborate effectively in a cross-functional, fast-paced start-up environment.

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 by this job include close vision and distance vision. While performing the duties of this job, the employee is regularly required to walk, stand, move, sit, carry, bend, kneel, reach, push, pull, lift, use hands and fingers, handle, or feel and talk and hear.

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

The work environment will be a mix of a typical office environment, laboratory space, manufacturing floor and construction site. Noise levels vary and include normal office noise, laboratory sounds (e.g., ventilation systems, equipment operation), manufacturing floor noise (e.g., machinery, forklifts), 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.