Materials Engineer

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.

Position Overview:

We are seeking a hands-on, detail-oriented Materials or Process Chemical Engineer to support the development and scale-up of advanced materials used in magnetics manufacturing, particularly high-performance rare earth permanent magnets. The ideal candidate will have expertise in high-temperature processing, solid-state chemistry, and rare earth metallurgy, and will play a key role in optimizing processes such as calcination, sintering, pressing, and annealing to produce high-quality magnetic materials at scale.

Key Responsibilities:

• Develop, optimize, and scale high-temperature solid-state processes critical to magnet production, including powder synthesis, calcination, sintering, and post-processing (e.g., annealing).
• Support rare earth materials handling, including separation, purification, and alloying of elements such as Nd, Pr, Dy, and Tb for magnet-grade alloys.
• Scale lab- and pilot-scale processes to industrial production while maintaining consistency, yield, and magnetic properties.
• Apply knowledge of thermodynamics, reaction kinetics, and heat/mass transfer to refine process parameters.
• Use Design of Experiment (DOE) methodologies (e.g., Taguchi) to improve material performance and reduce variability.
• Work with cross-functional teams in R&D, quality, and production to ensure robust technology transfer and process reliability.
• Contribute to continuous improvement initiatives and support root-cause analysis for process deviations or quality issues.

Required Qualifications:

• B.S. or M.S. in Chemical or Materials Engineering, with relevant coursework or thesis in materials science, inorganic chemistry, ceramic engineering, or a related field.
• Experience in high-temperature processing techniques such as sintering, calcination, pressing, and annealing.
• Familiarity with rare earth chemistry, especially as it pertains to magnet materials (e.g., NdFeB, SmCo).