Senior Machining Process Engineer - R&D

About the role

Vulcan Elements is at the forefront of producing American rare-earth permanent magnets, playing a vital role in enhancing national security and economic resilience. Our focus is on supporting critical industries, including defense, aerospace, and automotive sectors. We are in search of an experienced engineer who will oversee the machining and finishing processes for sintered NdFeB magnets, ensuring that our production meets the highest quality standards.

Key facts

What you'll do

• Assume responsibility for key performance indicators related to machining and finishing processes, transforming sintered magnet blocks into finished components that are ready for coating.
• Evaluate and optimize machining pathways, including techniques such as wire sawing, precision grinding, and tumbling, to improve both efficiency and product quality.
• Enhance existing machining methods, including slicing, grinding, and surface preparation, while also selecting and qualifying new shaping processes from laboratory development to production handover.
• Perform process characterization, metrology, and quality evaluations to establish baseline measurements and implement data-driven strategies to reduce defect rates.
• Assess and specify new machining and finishing technologies, including conducting vendor trials and establishing acceptance criteria, while documenting processes for future reference.
• Streamline current machining practices to minimize material waste and maximize yield, all while adhering to specified tolerances and performance objectives.
• Innovate and develop tooling and fixtures as necessary, and evaluate how surface characteristics affect coating adhesion and the overall performance of magnets.
• Collaborate with cross-functional teams to ensure alignment of machining processes with broader R&D goals and production requirements.

Requirements

• A Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Materials Science, or a related field, or equivalent hands-on experience.
• At least 5 years of experience in process engineering with a focus on machining and finishing operations.
• A solid history of managing machining processes from initial development stages through to full production implementation.
• Direct experience with sintered magnets, technical ceramics, or other brittle materials is highly preferred; however, candidates with significant grinding experience may also be considered.
• Candidates must be classified as a U.S. Person due to access requirements for U.S. export-controlled information or facilities.

Nice to have

• Experience or familiarity with semiconductor wafering, optics fabrication, or the manufacturing of cutting tools.
• Knowledge of advanced machining technologies or innovative manufacturing processes.
• Understanding of industry standards and best practices in machining and finishing operations.

Skills & tools

• Proficient in abrasive machining techniques for hard and brittle materials.
• Familiarity with diamond tooling specifications, including applications for wire and wheel.
• Competent in machine setup, alignment, and troubleshooting processes.
• Understanding of coolant chemistry and filtration systems to optimize machining operations.
• Strong analytical abilities in statistics, designed experiments, and process capability assessments.
• Proficient in precision dimensional and surface metrology, including the interpretation of GD&T (Geometric Dimensioning and Tolerancing).
• Ability to design and refine workholding and fixture solutions using CAD software such as SolidWorks or Fusion 360.

Practical notes

This role necessitates strict compliance with laboratory safety protocols. Employees are required to wear appropriate personal protective equipment (PPE), including lab coats, safety glasses, and gloves. The position involves working with machinery that presents cut hazards and other physical risks associated with machining activities. A strong commitment to maintaining a safe work environment and adhering to safety training protocols is essential for success in this position.

At Vulcan Elements, we are dedicated to fostering an inclusive and innovative work environment. If you are a motivated individual with a passion for engineering and a desire to contribute to the advancement of critical technologies, we encourage you to apply and become a part of our mission to support national security and economic stability through advanced manufacturing processes.