R&D Materials & Process Engineer

Vulcan Elements is manufacturing American rare-earth permanent magnets for a secure, resilient future. With a focus on national security and economic resiliency, we serve critical industries such as defense, aerospace, and automotive powering a high-technology future. Vulcan Elements is building a team of ambitious professionals committed to Mission Focus, Technical Excellence, and Transparency. 
 
We are seeking a driven R&D Materials & Process Engineer specializing in rare-earth permanent magnet fabrication. In this role, you will lead the practical process development, optimization, and scale-up of sintered NdFeB (Neodymium Iron Boron) magnet manufacturing. You will focus heavily on refining the end-to-end powder metallurgy pipeline—from alloy melting through powder preparation, alignment, sintering, and heat treatment.
You will act as the bridge between metallurgical research and full-scale factory execution, establishing robust processing windows, driving yield improvements, and translating laboratory innovations into scalable manufacturing operations.
 
Responsibilities

• Design and refine core processing steps, including Strip Casting, Hydrogen Decrepitation, Jet Milling & press parameters as they relate to process throughput, yield, downstream processing and final magnetic properties.
• Develop and fine-tune vacuum sintering profiles/thermal cycles as they relate to microstructural features and final magnetic performance.
• Desing of Experiments for improvement in magnetic performance, process throughput and yield, and cost improvement.
• Conduct root-cause failure analysis (RCA) to eliminate processing defects
• Support the scaling up of validated experimental processes from lab/pilot-scale equipment to full commercial production lines
• Collaborate closely with production and equipment engineering teams to modify existing tooling or specify requirements for next-generation processing equipment.

Responsibilities and tasks outlined are not exhaustive and may change as determined by the needs of the business

Qualifications

• Bachelor's degree in Materials Science, Metallurgical Engineering, Physics, or Process Engineering.
• 3+ years of direct experience in process engineering or industrial R&D environment
• Deep practical knowledge of powder metallurgy, vacuum thermal processing, and metal powder pressing.
• Hands-on experience operating, troubleshooting, or optimizing industrial processing equipment.
• Strong proficiency with magnetic testing systems (Hysteresisgraph, Pulsed Field Magnetometry) and material characterization tools (SEM/EDS, XRD, particle size analyzers).
• Proven track record applying DOE, Six Sigma methodologies, and statistical tools (e.g. Python, or JMP) for data analysis.

Must be a U.S. Person due to required access to U.S. export-controlled information or facilities.

Preferred Skills

• Direct experience with sintered NdFeB magnet manufacturing or design
• Direct experience with inert gas handling systems, oxygen-controlled environments, and powder oxidation prevention techniques.
• Experience with automated material handling or pressing tooling design for high-volume magnet manufacturing.

Physical and Environmental Requirements

The position requires regular presence on the production floor and the ability to navigate all areas of the facility. Candidates must be able to climb stairs, stand and walk for extended periods, and work in environments that may be hot, humid, or noisy. The role also requires the use of personal protective equipment, including respirators, and adherence to all applicable safety policies, procedures, and regulatory requirements. Employees must be able to complete required fit testing, wear appropriate PPE for the duration of assigned tasks, and respond safely to changing conditions within the production environment.