Project Engineer, Process Engineer

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:

• Build Solutions – 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.
• Deliver Quality – 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.
• Lead responsibly – 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.
• Win Together – 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.

The Project Engineer leads capital projects, process improvements, and equipment upgrades within a high‑temperature metal‑making and alloy environment. This role bridges operations, maintenance, and technical engineering teams to ensure projects are delivered safely, efficiently, and with long‑term reliability in mind. The ideal candidate is hands‑on, analytical, and comfortable working in a heavy industrial setting.

As part of this role, you will be required to travel to our UK site for an initial training period. During this time, you will learn Less Common Metals’ processes, standards, and operating methods. You will then serve as the trainer and project team lead within Engineering for the US site once operations commence, ensuring knowledge transfer and consistent global standards.

• Develop and manage project scopes, budgets, schedules, and risk registers for projects.
• Coordinate internal stakeholders, contractors, and OEMs to ensure alignment and timely execution.
• Lead project meetings, track milestones, and provide progress reports to leadership.
• Oversee installation, commissioning, and handover of new equipment and systems.

• Provide engineering support for melting, casting, rolling, forging, or heat‑treating operations.
• Analyze process data to identify bottlenecks, inefficiencies, and improvement opportunities.
• Support equipment specification, design reviews, and acceptance testing for furnaces, cranes, conveyors, and automation systems.
• Conduct root‑cause analysis (RCA) and implement corrective actions for equipment failures or process deviations.
• Ensure engineering documentation (P&IDs, layouts, manuals, drawings) is accurate and up to date.

• Ensure all project activities comply with site safety rules, UK regulations, and environmental standards.
• Lead hazard assessments (HAZOP, HIRA, PUWER) and implement engineering controls.
• Support continuous improvement of safety systems in…