Process Engineering – Macro Machining

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:

Position Overview: The Process Engineer – Macro Machining is responsible for developing, optimizing, and sustaining machining processes used to shape and size larger magnet components or assemblies. This role ensures dimensional accuracy, throughput, and surface quality by managing cutting parameters, tooling, fixturing, and process controls. Engineer supports production operations, leads troubleshooting, and drives continuous improvement across machining centers and related equipment.

Key Responsibilities:

·       Machining Process Development & Optimization - Develop and refine milling, turning, grinding, or sawing processes for larger magnet parts. Establish machining parameters (speed, feed, depth of cut, coolant flow, tool paths) for robust, repeatable performance. Optimize for dimensional accuracy, surface finish, and minimal chipping or cracking in brittle materials.

·       Tooling & Fixturing Development - Specify cutting tools, wheels, inserts, and fixtures suitable for magnet or special-material machining. Design or improve holding systems (clamps, jigs, soft jaws, magnetic/vacuum fixtures). Improve changeover efficiency and reduce setup variability.

·       Process Monitoring & Control - Maintain SPC on critical dimensions, flatness, concentricity, and tolerances. Track tool life, vibration, coolant condition, and machine performance. Ensure consistent machining performance across shifts and machines.

·       Troubleshooting & Root-Cause Analysis - Resolve issues such as poor surface finish, out-of-tolerance dimensions, chipping, breakage, or excessive tool wear. Use structured problem-solving methods (DOE, 5 Why’s, Fishbone) to implement corrective actions.

·       Equipment & Maintenance Support - Work with maintenance on machining centers, grinders, saws, and material-handling equipment. Support calibrations, alignment checks, PM routines, and machine restorations. Evaluate upgrades or new machining equipment for capability and capacity.

·       Material Handling & Protection - Define proper handling, staging, and transportation of larger magnet components to prevent damage. Ensure alignment with downstream processes such as grinding, coating, or assembly.

·       Quality Assurance Collaboration - Define measurement methods using calipers, micrometers, bore gauges, CMMs, or optical systems. Establish sampling plans and acceptance criteria for key dimensions and surface characteristics. Support failure analysis for machining-related defects.

·       Documentation & Standards - Create/update SOPs, machining recipes, control plans, PFMEAs, and process flow diagrams. Maintain tooling libraries, fixture drawings, and process change records.

·       New Product Introduction (NPI) - Support prototype machining, capability studies, and development of machining standards for new magnet designs. Transition successful trials to full-scale production.

·       Safety & Continuous Improvement - Ensure safe operation of machining equipment, including coolant handling, chip control, and lifting operations. Lead improvement projects focused on cycle-time reduction, scrap reduction, and tool-life extension.

Knowledge, Skills &Abilities:

·       Experience with machining brittle or hard materials (magnets, ceramics, sintered metals).

·       Familiarity with CNC machining centers, grinders, and precision metrology.

·       Knowledge of lean manufacturing and ISO9001/IATF16949.

Minimum Requirements:

·       Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, or related field.

·       2–5+ years of machining or manufacturing engineering experience.

·       Strong understanding of machining fundamentals, GD&T, and tooling interactions.

·       Experience with SPC and structured problem-solving.

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.

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.