Analysis Engineer - Process Modeling

About the role

Vulcan Elements is dedicated to producing American rare-earth permanent magnets to support national security and economic stability. We are seeking an Analysis Engineer with expertise in Process Modeling to develop, implement, and refine physics-based simulations for our NdFeB permanent magnet manufacturing processes. This role involves creating detailed computational models to analyze fluid flow, heat transfer, electromagnetic effects, and mechanical responses within manufacturing systems. The goal is to identify process improvements, optimize production parameters, and support product innovation through accurate and validated simulations. The ideal candidate will work closely with cross-disciplinary teams, including process engineers, materials scientists, and data analysts, to translate modeling insights into actionable process enhancements.

Key facts

What you'll do

• Develop comprehensive models to simulate thermal behavior during key manufacturing steps such as sintering, heat treatment, casting, and powder processing.
• Create and execute simulations that focus on fluid dynamics, heat transfer, electromagnetic phenomena, and mechanical stresses to better understand process conditions.
• Use physics-based models alongside process data to identify bottlenecks, inefficiencies, and potential failure modes, enabling targeted process improvements.
• Build, validate, and refine simulations using advanced commercial software such as ANSYS (Mechanical, Maxwell, ROCKY, Fluent), COMSOL Multiphysics, or similar tools.
• Collaborate with process, materials, and data engineers to incorporate simulation results into development workflows, ensuring models accurately reflect real-world conditions.
• Design and conduct sensitivity analyses to evaluate how variations in process parameters impact outcomes, helping to optimize manufacturing settings.
• Document modeling assumptions, boundary conditions, validation procedures, and results in accordance with quality management systems and project documentation standards.
• Develop custom scripts, automation routines, and data processing tools using Python, MATLAB, or other scripting languages to streamline simulation workflows and analyze large datasets efficiently.
• Participate in cross-functional meetings to communicate modeling insights, present findings, and recommend process adjustments based on simulation outcomes.
• Support experimental work by providing modeling guidance, predicting process responses, and interpreting experimental data to validate simulation accuracy.
• Assist in troubleshooting process issues by applying modeling techniques to simulate potential causes and recommend corrective actions.
• Contribute to continuous improvement initiatives by exploring innovative modeling approaches, microstructure evolution techniques, and coupled multiphysics simulations.
• Ensure all modeling activities comply with safety standards, quality protocols, and export control regulations, especially considering the handling of sensitive materials and information.

Requirements

• Bachelor's degree or higher in Mechanical Engineering, Aerospace Engineering, Materials Science and Engineering, or a related technical discipline.
• Proven experience in constructing, validating, and applying process models using ANSYS (Mechanical, Maxwell, ROCKY, Fluent), COMSOL Multiphysics, or comparable simulation software.
• Strong understanding of computational fluid dynamics (CFD), heat transfer, electromagnetic modeling, and mechanical stress analysis.
• Proficiency in scripting languages such as Python, MATLAB, or similar to automate simulations, process data, and develop custom analysis routines.
• Demonstrated ability to work independently, manage multiple modeling projects simultaneously, and meet deadlines.
• Excellent communication skills to effectively present complex modeling results to multidisciplinary teams and document findings clearly.
• Experience with manufacturing processes such as sintering, casting, powder compaction, forging, or heat treatment is highly desirable.
• Ability to interpret process data and incorporate it into models to improve accuracy and predictive capability.
• Knowledge of microstructure evolution modeling, phase-field methods, or CALPHAD techniques is a plus.
• Familiarity with multiphysics coupling, including thermo-mechanical, fluid-structure interaction, or electromagnetic-thermal simulations.
• Experience working in industrial, research, or development environments with an understanding of manufacturing constraints and process validation.

Nice to have

• Experience modeling metal manufacturing processes such as sintering, casting, powder handling, or forging.
• Familiarity with particle interaction modeling, granular flow, or discrete element methods (DEM).
• Background in electromagnetic simulation, especially for magnetic field analysis and electromagnetic process design using ANSYS Maxwell or similar tools.
• Knowledge of microstructure evolution modeling techniques, including phase-field or CALPHAD approaches.
• Experience with coupled multiphysics simulations involving thermal, mechanical, electromagnetic, and fluid interactions.
• Understanding of high-performance computing (HPC), GPU acceleration, or cloud-based simulation platforms to handle large-scale models efficiently.
• Prior experience in a production, industrial, or R&D setting, with insights into manufacturing constraints, process validation, and quality assurance.

Skills & tools

• ANSYS (Mechanical, Maxwell, ROCKY, Fluent)
• COMSOL Multiphysics
• Python, MATLAB, or similar scripting languages
• Computational fluid dynamics (CFD)
• Heat transfer and thermal modeling techniques
• Electromagnetic simulation methods
• Mechanical stress and structural analysis
• Data analysis and automation scripting

Practical notes

Candidates must be U.S. Persons due to the necessity of accessing U.S. export-controlled information or facilities. The position requires strict adherence to safety protocols, including wearing appropriate PPE such as lab coats, safety glasses, gloves, and other protective gear when working with chemicals or hazardous materials. The role involves handling potentially hazardous substances and equipment, necessitating compliance with all safety regulations and procedures. Employees are expected to complete safety training, maintain a clean and organized workspace, and report unsafe conditions immediately. The work environment may include laboratory or manufacturing settings where safety and security are paramount. Candidates should demonstrate a strong commitment to safety, quality, and regulatory compliance in all activities.