Process Engineer - Milling na USA Rare Earth

Job Summary:

We are seeking a Process Engineer – Milling to lead the design and control of metal powder milling processes within our fast-growing magnet manufacturing start-up. This role will oversee the transformation of strip-cast feedstock through decrepitation, tumble milling, and jet milling to powder delivery for pressing, ensuring precise particle size distribution, surface oxidation control, and consistent powder quality. You’ll play a key role in optimizing process performance and supporting reliable downstream operations in a dynamic, high-growth production environment.

Key Responsibilities

·       Develop and maintain process parameters for tumble and jet mills to achieve target particle size distribution, morphology, and flowability.

·       Monitor oxygen, moisture, and contamination levels throughout powder handling and storage.

·       Collaborate with R&D and quality on powder characterization, sampling, and analysis methods.

·       Specify and maintain equipment for air classification, dust collection, and loading systems.

·       Conduct PFMEA and establish control plans for powder processes; maintain documentation.

·       Lead continuous improvement initiatives to reduce contamination risk and enhance powder yield.

·       Support automation or containment improvements for dust management and operator safety.

·       Collaborate with Pressing Engineer to ensure powder rheology and moisture content support stable pressing operations.

·       Assist with equipment vendor selection, FAT/SAT, and installation of new mills and classifiers.

·       Work with other groups to support the optimization of material handling methods between strip casting, milling, and slurry preparation.

Qualifications

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

·       3–5 years of experience in milling, powder metallurgy, or materials processing within a manufacturing environment.

·       Proficiency in process modeling, data analysis, and statistical process control (SPC).

·       Strong problem-solving and troubleshooting skills related to particle quality and process efficiency.

·       Knowledge of safety, quality, and industry standards for powder and materials processing.

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