R&D Process Development 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

The R&D Process Development Engineer is responsible for designing, developing, and optimizing R&D laboratory processes to support new product development and scale-up. This role works closely with cross-functional teams including R&D scientists, manufacturing, quality, and product development to ensure innovative ideas are translated into efficient, scalable, and high-quality production processes. The engineer will apply technical expertise, data-driven problem solving, and creative thinking to deliver robust solutions that support the company’s innovation pipeline and long-term growth.

Key Responsibilities:

- Design, develop, and optimize new processes to support product development and commercialization.

- Collaborate with R&D, manufacturing, and quality teams to transition lab-scale concepts into pilot- and full-scale operations.

- Evaluate process performance, analyze data, and apply statistical/engineering methods to drive improvements in yield, quality, efficiency, and cost.

- Create and maintain process documentation, including standard operating procedures (SOPs), technical reports, and process flow diagrams.

- Lead root cause investigations and implement corrective/preventive actions for process-related issues.

- Identify and integrate new technologies, equipment, and methods to improve development capabilities.

- Ensure compliance with safety, regulatory, and quality standards in all process development activities.

- Provide technical support for scale-up, technology transfer, and manufacturing troubleshooting.

Experience and Skills:

- Bachelor’s or Master’s degree in Chemical Engineering, Mechanical Engineering, Materials Science, or related field.

- 2+ years of experience in process development, R&D engineering, or manufacturing environment (internship or co-op experience may be considered).

- Strong understanding of process engineering principles, experimental design, and data analysis.

- Hands-on experience with lab- and pilot-scale equipment and process troubleshooting: particle size analyzer, light optimal microscope, pucking, polishing, powder pressing, vaccum sintering, hand held measurement equipment, cut off saws and surface grinders.

- Familiarity with statistical process control (SPC), Design of Experiments (DOE), and continuous improvement methodologies.

- Excellent problem-solving, communication, and collaboration skills.

- Ability to work in a fast-paced, cross-functional team 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, climb stairs and ladders, work in elevated platforms, use hands and fingers, handle, or feel and talk and hear. May be required to lift and move boxes or packages not exceeding 40 pounds in weight. Some work stress inherent to the position and extended work hours may be required.

WORK ENVIRONMENT:

Work will mainly be conducted in laboratory and manufacturing settings. This may include exposure to extremes in temperature and humidity, moving mechanical parts, risk of electrical shock, toxic chemicals, explosives, fumes, confined space, or airborne particles.

Personal protective equipment is required when performing work in the manufacturing plant environment, including hard hat, hearing protection, safety glasses, safety footwear, and as needed, respirator, rubber steel-toe boots, protective clothing, gloves, Arc flash gear, and any other protective equipment, as required.

DISCLAIMER:

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.