Process Engineer – Micro-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:

We are seeking a Process Engineer – Micro-Machining to lead the design, operation, and optimization of all micro-machining processes within our fast-growing magnet manufacturing start-up. This role will oversee high-volume precision material slicing, component shaping, and finishing operations, ensuring tight dimensional tolerances, surface quality, and process stability. You’ll play a key role in developing and maintaining efficient, repeatable processes while supporting consistent product quality and reliable downstream operations in a dynamic, high-growth production environment.

Key Responsibilities

• Own operation and design of micro machining equipment and processes.
• Ensure small parts meet strict dimensional, surface finish, and edge preparation requirements.
• Implement and maintain automation systems to maximize throughput and minimize handling.
• Oversee pre-inspection cleaning, tumbling, slicing, grinding, and chamfering.
• Maintain SOPs, process documentation, and FMEAs for micro machining.
• Collaborate with maintenance for preventive maintenance and troubleshooting.
• Monitor quality metrics and SPC data to ensure process control.
• Participate in equipment procurement, FAT/SAT, and vendor evaluation.
• Train operators and junior engineers in precision machining, inspection, and safety protocols.
• Interface with downstream coating engineers to ensure parts are ready for plating.

Qualifications

• Bachelor’s degree in Mechanical Engineering, Chemical Engineering, Materials Science, or a related field (advanced degree preferred).
• Experience in micro-machining, precision part manufacturing, or related processes.
• Strong analytical and problem-solving skills, including data analysis and SPC.
• Proficiency in operating and optimizing micro-machining equipment and processes, emphasis on diamond abrasive slicing and grinding for shaping.
• Knowledge of dimensional tolerances, surface finish, and precision inspection.
• Familiarity with SOPs, process documentation, FMEAs, and quality control.
• Ability to collaborate effectively with cross-functional teams in a fast-paced start-up environment.
• Experience with automation, part handling, and training operators or junior engineers is a plus.

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.