Process Engineer

Process Engineers (Multiple Openings – Specialized Manufacturing Areas) Who We Are

USA Rare Earth is building the first fully integrated, U.S.

-based “mine-to-magnet” rare earth supply chain. Our mission is to become the leading Western supplier of high-value rare earth magnets and critical minerals supporting energy, mobility, and national security.

Through the strategic development of the Round Top heavy rare earth deposit in West Texas, a rare‑earth separation facility, and the United States’ first rare‑earth magnet manufacturing facility, we are creating a vertically integrated, scalable, and domestic solution.

USA Rare Earth is hiring multiple Process Engineers across several specialized manufacturing disciplines.

These roles support daily production operations, drive process optimization, improve quality, and reduce waste across magnet manufacturing processes.

All positions are hands‑on roles in production/manufacturing and require direct engagement with equipment, operators, and daily manufacturing operations.

• 2–5+ years of experience in surface finishing, coating, or electroplating within a manufacturing environment.
• Strong knowledge of electrochemical processes, corrosion mechanisms, surface science, and coating behavior.
• Experience operating and interpreting results from SEM, XRF, and other coating‑analysis equipment.
• Familiarity with IATF 16949 and/or ISO 9001 quality systems and process control methodologies.
• 2–5+ years of experience in thermal processing, including vacuum sintering (required) and heat treatment.
• Strong knowledge of vacuum furnace systems, thermal cycle development, and furnace system design.
• Experience optimizing temperature uniformity, atmosphere control, and cooling systems.
• Understanding of upstream/downstream process integration within thermal manufacturing environments.

• 2–5+ years of experience in heat treatment, coating, diffusion, or materials processing environments.
• Hands‑on experience with vacuum furnaces and diffusion furnace operations.
• Understanding of rare‑earth magnet microstructures and diffusion behavior, including microstructure analysis.
• Familiarity with IATF 16949 and/or ISO 9001 quality systems.
• 2–5+ years of machining or manufacturing engineering experience in high‑volume production.
• Experience machining brittle or hard materials (magnets, ceramics, sintered metals) using CNC machines and grinders.
• Strong understanding of machining fundamentals, GD&T, and precision metrology.
• Familiarity with IATF 16949 and/or ISO 9001 standards.
• 2–5+ years of machining, micro‑machining, precision grinding, EDM, or laser processing experience.
• Experience in machining brittle or hard materials (magnets, ceramics, glass, ferrites, hard alloys).
• Proficiency in precision metrology (CMM, optical, laser) and tight tolerance control.
• Strong understanding of GD&T and IATF 16949 and/or ISO 9001 standards.

• 2–5+ years of manufacturing engineering experience in powder processing or materials manufacturing.
• Experience operating attritors, jet mills, classifiers, and vacuum handling systems.
• Understanding of powder behavior, green strength characteristics, and mechanical tolerances.
• Familiarity with IATF 16949 and/or ISO 9001 quality systems.

• 2–5+ years of manufacturing engineering experience, preferably in powder pressing or compaction processes.
• Experience with uniaxial presses, feed systems, and green machining equipment.
• Understanding of green strength behavior, density control, and mechanical tolerances prior to sintering.
• Familiarity with IATF 16949 and/or ISO 9001 quality systems.
• Bachelor’s degree in Mechanical Engineering, Chemical Engineering, Materials Science, Manufacturing Engineering, or related technical field.
• 2–5+ years of relevant manufacturing or production engineering experience.
• Strong problem‑solving and data analysis skills (SPC, root cause analysis, statistical methods).
• Ability to work cross‑functionally in a fast‑paced production environment.

These roles operate in a manufacturing production environment with direct interaction with equipment and operators. Extended hours may be required during critical production phases.

USA Rare Earth proudly supports Equal Employment Opportunities. We provide equal employment opportunities to all applicants and reasonable accommodations in accordance with applicable federal, state, and local laws.

For assistance applying due to a disability, please contact People & Culture at .