Process Engineer - Pressing bei USA Rare Earth

Job Summary:

We are seeking a Process Engineer – Pressing to lead the design, operation, and optimization of all pressing processes within our fast-growing magnet manufacturing start-up. This role will oversee operations from jet-milled powder through pressing, green part handling, and cutting, ensuring process stability, magnetic alignment, and uniform green density. You’ll play a key role in managing recycles and slurry systems while driving consistent product quality and efficient downstream operations in a dynamic, high-growth production environment.

Key Responsibilities

·       Define and maintain slurry preparation and wet pressing parameters to achieve consistent green density and orientation.

·       Oversee press setup, tooling design, and magnetic field application during pressing.

·       Develop processes for green cutting, trimming, and part separation.

·       Establish handling methods to minimize green part damage prior to sintering.

·       Manage green recycles and slurry re-use processes, ensuring quality control.

·       Develop and maintain SOPs, FMEAs, and control documentation.

·       Analyze press data (force, alignment, density) and drive improvements in yield and process stability.

·       Interface with Maintenance and Facilities on press utilities, cooling, and magnetic field systems.

·       Collaborate with Furnace Engineer for pre-sintering loading and tray design.

·       Participate in equipment selection and qualification for presses and cutting systems. This includes both wet pressing systems and future dry pressing systems that have additional considerations.

Qualifications

·       Bachelor’s degree in Mechanical Engineering, Chemical Engineering, Materials Science, or a related field (advanced degree preferred).

·       3–5 years of experience in pressing, slurry handling, powder handling, or materials processing.

·       Proficiency in slurry preparation, wet pressing parameters, green part handling, and tooling/magnetic field setup.

·       Strong analytical and problem-solving skills, including data analysis and statistical process control (SPC).

·       Knowledge of SOPs, FMEAs, and quality control for pressing operations.

·       Ability to collaborate effectively with cross-functional teams in a fast-paced, start-up environment.

·       Experience managing complex equipment operations and optimizing process stability and yield.

Physical Demands

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. 

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

Noise level:

Exposure will vary and include normal office noise, typical 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.

The above statements are intended to describe the general nature and level of work being performed by people assigned to this job. They are not intended to be an exhaustive list of all responsibilities, duties, skills required of personnel so classified. The reporting relationship may not reflect the most recent changes to the corporate reporting structure.

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, [email protected], to discuss reasonable accommodations.