R&D Process Development Engineer at Careers at USA Rare Earth

Position Overview

The R&D Process Development Engineer is responsible for designing, developing, and optimizing R&D laboratory processes to support new product development and scale-up. This role works closely with cross-functional teams including R&D scientists, manufacturing, quality, and product development to ensure innovative ideas are translated into efficient, scalable, and high-quality production processes. The engineer will apply technical expertise, data-driven problem solving, and creative thinking to deliver robust solutions that support the company’s innovation pipeline and long-term growth.

Key Responsibilities:

·       Design, develop, and optimize new processes to support product development and commercialization.

·       Collaborate with R&D, manufacturing, and quality teams to transition lab-scale concepts into pilot- and full-scale operations.

·       Evaluate process performance, analyze data, and apply statistical/engineering methods to drive improvements in yield, quality, efficiency, and cost. 

·       Create and maintain process documentation, including standard operating procedures (SOPs), technical reports, and process flow diagrams.

·       Lead root cause investigations and implement corrective/preventive actions for process-related issues.

·       Identify and integrate new technologies, equipment, and methods to improve development capabilities.

·       Ensure compliance with safety, regulatory, and quality standards in all process development activities.

·       Provide technical support for scale-up, technology transfer, and manufacturing troubleshooting.

Experience and Skills:

·       Bachelor’s or Master’s degree in Chemical Engineering, Mechanical Engineering, Materials Science, or related field.

·       2+ years of experience in process development, R&D engineering, or manufacturing environment (internship or co-op experience may be considered).

·       Strong understanding of process engineering principles, experimental design, and data analysis.

·       Hands-on experience with lab- and pilot-scale equipment and process troubleshooting: particle size analyzer, light optimal microscope, pucking, polishing, powder pressing, vaccum sintering, hand held measurement equipment, cut off saws and surface grinders.

·       Familiarity with statistical process control (SPC), Design of Experiments (DOE), and continuous improvement methodologies.

·       Excellent problem-solving, communication, and collaboration skills.

·       Ability to work in a fast-paced, cross-functional team environment.

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, climb stairs and ladders, work in elevated platforms, use hands and fingers, handle, or feel and talk and hear. May be required to lift and move boxes or packages not exceeding 40 pounds in weight. Some work stress inherent to the position and extended work hours may be required. 

WORK ENVIRONMENT:  

Work will mainly be conducted in laboratory and manufacturing settings. This may include exposure to extremes in temperature and humidity, moving mechanical parts, risk of electrical shock, toxic chemicals, explosives, fumes, confined space, or airborne particles. 

Personal protective equipment is required when performing work in the manufacturing plant environment, including hard hat, hearing protection, safety glasses, safety footwear, and as needed, respirator, rubber steel-toe boots, protective clothing, gloves, Arc flash gear, and any other protective equipment, as required. 

DISCLAIMER:

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.