Senior Materials Engineer

About Electron Energy Corporation:

Electron Energy Corporation (EEC) is a world leader in the design and manufacturing of rare earth magnets for demanding applications in aerospace, defense, medical, and industrial markets. As part of Permag, EEC leverages deep materials expertise and vertically integrated capabilities to deliver high-performance magnetic solutions.

For more information on Electron Energy Corporation, please visit: https://www.electronenergy.com

Position Summary

The purpose of this role is to develop new processes and new permanent magnet material grades and continuously improve existing processes at the Material Technology Center (MTC), using an engineering approach offering solutions that increase safety, cost effectiveness, production yields, and solutions that address manufacturing inefficiencies.

Major Responsibilities:

New Material Development

• Develop and optimize formulations for samarium-cobalt magnetic material.

• Research and evaluate manufacturing technologies to develop new magnet grades.

• Conduct microstructure, magnetic, mechanical, thermodynamic analysis using available equipment on site, at other locations, or outsource the testing to qualified labs.

• Utilize data analysis and statistical methods to assess material and process performance and outcomes.

• Utilize or acquire analytical equipment necessary to assess the performance of the newly developed material.

• Lead pilot projects for the qualification of the new materials.

New Process Technology

• Research and evaluate new manufacturing technologies to enhance magnet production capabilities.

• Submit Capital Acquisition Requisition (CAR) detailing the costs and benefits of proposed new equipment and technologies.

• Lead the installation and de-bugging of new equipment as required.

• Design equipment, cycles and software.

• Qualify new equipment and processes to validate performance and quality.

• Create pFEMAs and work instructions for new processes, for Quality approval.

• Develop plans for the integration of new technologies into existing manufacturing systems, ensuring minimal disruption to production.

• Lead pilot projects for the implementation of new technologies and processes at MTC.

Continuous Improvement

• Utilize Lean and Six Sigma methodologies to identify opportunities for process improvement, collect data, document results, report findings.

• Conduct root cause analysis on process failures and implement corrective actions.

• Monitor process performance and implement continuous improvement initiatives to enhance efficiency and reduce waste.

• Develop processes to improve cost, throughput and quality.

• Recommend process change to improve production.

• Stay updated with the latest advancements in materials science and magnetic technologies.

Production Support

• Oversee the melt, mill, powder, press, and sintering processes to ensure high-quality magnet production from engineering standpoint.

• Provide real-time technical support to production teams, helping to troubleshoot and resolve process-related issues.

• Analyze production data to identify trends and recommend process adjustments.

• Collaborate with Maintenance teams to ensure optimal equipment performance and minimize downtime.

• Review in-process or testing production data to confirm that the requirements are met.

• Advise schedulers / material controllers on the selection of appropriate materials for various production jobs as needed.

• Provide technical guidance and support to ensure proper material usage and handling.

Customer Support

• Interface with customers to understand their material requirements and provide technical guidance on product manufacturability.

• Address customer concerns related to manufacturing processes and quality, providing timely solutions.

• Work with the Quality assurance and Operations teams to resolve any product-related issues raised by customers.

• Recommend improvements to customers’ material design for manufacturability and performance by presenting data, calculations to support the recommendations.

• Contribute to the Business Development Group by providing estimated labor and, if needed, costs for manufacturing lead-time.

• Support other Research and Development projects.

Qualifications

• Required at minimum BS in Materials Science, Manufacturing Engineering, Industrial Engineering or Physics.

• Minimum 5 years’ work experience.

• High level expertise in Material Science, Powder Metallurgy principles, Material Testing and Failure Analysis.

• Proficiency with Microsoft Office and project tracking tools (e.g., MS Project, Celoxis)