Senior Materials & Process Engineer - Powder Metallurgy

About the role

Vulcan Elements is dedicated to manufacturing American-made rare-earth permanent magnets that bolster national security and promote economic stability. The company's mission focuses on producing high-quality magnetic materials for critical sectors such as defense, aerospace, and automotive industries. As part of our growth, we are seeking a highly skilled Senior Materials & Process Engineer to lead and optimize our powder metallurgy processes. This role involves working closely with cross-functional teams to develop, refine, and scale manufacturing techniques that meet stringent quality and performance standards. The successful candidate will play a key role in advancing our technological capabilities, ensuring process reliability, and contributing to innovative research efforts. The position offers an exciting opportunity to work at the forefront of magnetic materials manufacturing in a collaborative and mission-driven environment.

Key facts

What you'll do

• Take ownership of the entire powder metallurgy manufacturing process, including powder preparation, compaction, sintering, and thermal treatments, ensuring optimal process control and product quality.
• Lead efforts to improve existing production lines, increase efficiency, and develop new formulations for NdFeB (neodymium-iron-boron) magnets, addressing complex materials challenges associated with reactive metals.
• Analyze process variables such as temperature, atmosphere, pressure, and time, and evaluate their impact on magnetic properties, microstructure, and overall product performance.
• Conduct root-cause analysis for process defects, non-conformances, or inconsistencies, and implement corrective and preventive actions to maintain high-quality standards.
• Support the scale-up of new alloy compositions from pilot projects to full-scale manufacturing, ensuring reproducibility and process robustness.
• Collaborate with manufacturing teams to define technical specifications, select appropriate equipment, and assist with the commissioning of new machinery or process modifications.
• Utilize process data and statistical tools to optimize manufacturing parameters, reduce variability, and improve throughput.
• Document process procedures, work instructions, and quality control protocols, maintaining compliance with company standards and regulatory requirements.
• Participate in research and development initiatives aimed at developing innovative materials, processing techniques, and performance enhancements for magnetic products.
• Ensure all manufacturing activities adhere to safety policies, environmental regulations, and quality standards, fostering a safe and compliant work environment.
• Provide technical guidance and mentorship to junior engineers and operators, sharing expertise in powder metallurgy and materials processing.
• Engage in cross-disciplinary communication with R&D, quality, and production teams to align process development with product specifications and customer requirements.
• Keep abreast of advancements in powder metallurgy, magnetic materials, and related fields, integrating new knowledge into process improvements.
• Assist in troubleshooting production issues, providing technical support to resolve process bottlenecks or equipment failures.
• Support audits and inspections related to quality management systems and regulatory compliance.
• Contribute to continuous improvement initiatives, leveraging data analysis and process engineering principles to enhance overall manufacturing performance.

Requirements

• Bachelor's, Master's, or Ph.D. in Materials Science, Metallurgical Engineering, Chemical Engineering, or a closely related field.
• Minimum of 8 years of relevant experience in powder metallurgy, preferably within an industrial manufacturing environment focused on magnetic or reactive metal materials.
• Proven experience handling reactive metal powders, working with inert atmospheres (such as argon or nitrogen), and conducting vacuum heat treatments.
• Strong knowledge of materials characterization techniques, including scanning electron microscopy (SEM), X-ray diffraction (XRD), and thermal analysis methods like TGA/DSC.
• Demonstrated ability to design experiments, analyze data statistically, and lead research projects aimed at process development.
• Familiarity with process control tools, statistical process control (SPC), and quality management systems.
• Excellent problem-solving skills, with a track record of identifying root causes and implementing effective solutions.
• Strong communication skills to collaborate effectively with multidisciplinary teams and document technical procedures clearly.
• Ability to work in a fast-paced environment, managing multiple priorities while maintaining attention to detail.
• Must be a U.S. Person due to access restrictions related to export-controlled information or facilities.

Nice to have

• Direct experience in the production of sintered NdFeB permanent magnets, including grain boundary diffusion techniques.
• Ability to evaluate magnetic properties and interpret microstructural data to inform process adjustments.
• Familiarity with data analysis software such as Python, MATLAB, or JMP for analyzing process and quality data.
• Knowledge of industry standards such as ISO 9001 or IATF 16949, and experience participating in quality audits.
• Experience working in a regulated environment with strict compliance requirements related to export controls and ITAR regulations.
• Prior involvement in scaling laboratory or pilot processes to full manufacturing scale, ensuring reproducibility and process stability.

Skills & tools

• Powder metallurgy processing techniques, including powder handling, compaction, sintering, and thermal treatments.
• Materials characterization methods such as SEM, XRD, TGA/DSC, and microstructural analysis.
• Experimental design, statistical analysis, and process optimization.
• Data analysis and visualization software, including Python, MATLAB, or JMP.
• Quality management systems and process control tools.
• Strong troubleshooting and problem-solving skills in manufacturing environments.
• Effective communication and documentation abilities.

Practical notes

Candidates should be prepared for regular on-site presence at the Research Triangle Park facility, with the ability to navigate various areas of the manufacturing plant. The role requires standing, walking, and climbing stairs for extended periods, often in environments that may be hot, humid, or noisy. Personal protective equipment, such as respirators, safety glasses, and protective clothing, will be mandatory during certain activities, and adherence to all safety policies and procedures is essential. Employees must complete fit testing and wear appropriate PPE during assigned tasks. The position demands flexibility to respond to process issues, troubleshoot equipment, and implement improvements in a dynamic manufacturing setting. Strong communication skills are necessary to collaborate effectively across teams and document technical work accurately. The successful candidate will be committed to safety, quality, and continuous improvement, contributing to Vulcan Elements' mission of producing world-class magnetic materials.