Process Engineer

Process Engineer - Finish & Coating

Who we are:

We are on a mission to become the leading Western supplier of high value rare earth magnets and critical minerals through a supply chain that supports the future state of energy, mobility, and national security. Our dynamic solution solves key domestic rare earth production challenges through optimizing margins, enhancing efficiency, minimizing costs and mitigating technical challenges.

Our early mover advantage positions us to become the first vertically integrated ex-China rare earth supply chain through substantial interest in the Round Top heavy rare earth, lithium and critical minerals deposit in West Texas, a rare earth separation facility with proven extraction methods, and development of the United States’ first rare earth and critical minerals production facility, with scalable production capability. By developing this fully integrated, US-based “mine-to-magnet” critical mineral supply chain, we are poised to become the leading Western supplier.

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, while keeping safety, quality and excellence at the forefront in everything we do.

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 – Finishing & Coating is responsible for developing, optimizing, and sustaining all surface-preparation and coating processes used in magnet manufacturing. This role ensures that magnets meet performance, durability, corrosion-resistance, and quality requirements through robust process control, continuous improvement, and cross-functional collaboration. The engineer will support production operations, new product introduction, cost-reduction initiatives, and compliance with safety and environmental standards.

Key Responsibilities:

- Surface Preparation Process Development -

Define and optimize processes such as cleaning, degreasing, blasting, etching, and activation. Ensure consistent surface condition, cleanliness, and roughness prior to coating.

- Coating Process Design and Control -

Develop, implement, and maintain finishing processes such as: Ni/Cu/Ni plating Zn, epoxy, phosphate coatings Parylene, e-coating, or specialized protective coatings. Establish process parameters, work instructions, and recipe controls.

- 3. Quality Assurance & Testing -

Ensure coating performance meets functional requirements (adhesion, thickness, corrosion resistance, appearance). Lead and interpret testing such as XRF thickness, SST, cross-section microscopy, adhesion/tape testing, and thermal cycling. Implement SPC and control plans.

- Troubleshooting and Root-Cause Analysis -

Investigate coating defects (peeling, blistering, pitting, porosity, oxidation, uneven coating). Use structured tools such as 8D, 5 Why’s, DOE, Fishbone diagrams to drive corrective actions.

- Chemical Bath and Process Maintenance -

Monitor and adjust bath chemistry, pH, temperature, concentrations, and contamination levels. Work with suppliers on chemical life extension, replenishment schedules, and cost optimization.

- New Product Introduction (NPI) -

Support trials and qualification of new magnet designs, materials, and coatings. Conduct capability studies and ensure manufacturability. Create prototype coating plans and documentation.

- Equipment & Automation Support -

Collaborate with equipment engineers on maintenance, calibration, and upgrades of coating lines, ovens, curing stations, and chemical dosing systems. Support automation improvements to reduce scrap and increase throughput.

- Documentation & Standards Management -

Create and update SOPs, PFMEAs, control plans, process flow diagrams, and training materials. Ensure documents meet ISO9001 / IATF16949 or customer audit requirements.

- Documentation & Standards Management -

Create and update SOPs, PFMEAs, control plans, process flow diagrams, and training materials. Ensure documents meet ISO9001 / IATF16949 or customer audit requirements.

- Documentation & Standards Management -

Create and update SOPs, PFMEAs, control plans, process flow diagrams, and training materials. Ensure documents meet ISO9001 / IATF16949 or customer audit requirements.

Knowledge, Skills & Abilities:

- Experience with rare-earth magnet manufacturing (NdFeB preferred).

- Background in plating line automation or high-volume manufacturing.

- Familiarity with IATF16949, ISO9001, and automotive-quality systems.

- Experience using SEM, XRF, and other coating-analysis equipment.

Minimum Requirements:

- Bachelor’s degree in chemical engineering, Materials Science, Mechanical Engineering, or related field.

- 2–5+ years of experience in surface finishing, coating, or electroplating (preferably in magnet or metals manufacturing).

- Strong knowledge of chemical processes, corrosion mechanisms, surface science, and coating technologies.

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 an office environment. Noise level: Normal office noises

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