Process Engineer - Milling

Who We Are:

We are on a mission to become a leading supplier of critical materials that enable the green energy and technology revolution.  Our materials and technologies are required for the electric vehicle, green energy, consumer electronics, and defense industries, and our battery grade lithium and tech metals are needed for chipsets, semiconductors, and 5G. 

We have a substantial interest in the Round Top, Heavy Rare Earth, Lithium and Critical Minerals deposit in West Texas. We have also developed the United States’ first rare earth and critical minerals processing facility and we own the only scalable, sintered neo-magnet manufacturing system in the Western Hemisphere. By developing this fully integrated, US-based “mine-to-magnet” critical mineral supply chain, we are poised to become the leading domestic supplier to these industries.

What You Can Expect:

At USA Rare Earth, we are pioneers and problem solvers, technologists and team players. Together, we:

Build Solutions: If our task was a simple one, it would already be done. We are creative and solution-oriented, and we think outside the box to solve important problems. We know that a range of expertise and technologies is needed for success, and we work across sectors and alongside customers to deliver world-class solutions in sustainable ways.

Deliver Quality: When we do things, we do them well. We believe that top-tier quality leads to industry competitiveness and we hold ourselves to the highest quality standards. We move fast when executing, but safety, quality, and excellence always come first.

Lead responsibly: We have a responsibility to the planet, our consumers, our country, and each other. We put safety at the center of all we do, take accountability for our actions, incorporate sustainable practices in our processes and act with the financial best interest of our investors and consumers in mind.

Win Together: Establishing a rare earth magnet supply chain is a big undertaking – and getting there is a team effort. We communicate openly, work together and challenge each other in pursuit of our goals. With every step we take we learn and get better.

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, hr@usare.com, to discuss reasonable accommodations.