Materials Process Engineer - Metals in Durham

Energy Jobline ZR; Durham (NC); On-site; USD 100,000 - 150,000; Full time

Job summary

Vulcan Elements is seeking a Materials and Process Engineer to develop and validate computational models for thermal, fluid, and electromagnetic phenomena in magnet manufacturing. The role starts in Durham, NC, moving to Benson, NC as the new facility comes online.

You will build simulations with ANSYS/COMSOL, process data to optimize manufacturing steps, and collaborate with process, materials, and data engineers. Strong CFD, heat transfer, and scripting skills are essential.

Qualifications

• BS or higher in Mechanical Engineering, Aerospace Engineering, Materials Science, or related field.
• Experience building and validating process models using ANSYS/COMSOL or similar.
• Strong CFD, heat transfer, and stress/strain modeling knowledge.
• Python or MATLAB scripting for simulation setup and data processing.
• Ability to work independently and communicate results to cross-functional teams.

Responsibilities

• Model thermal conditions during manufacturing processes such as sintering, heat treatment, and casting.
• Create models for fluid dynamics, heat transfer, mechanical, and electromagnetic phenomena.
• Use models with process data to drive process improvement.
• Build and refine simulations using ANSYS, COMSOL, or equivalent.
• Collaborate with process, materials, and data engineers to integrate outputs.
• Design simulation studies to evaluate sensitivities and guide experiments.
• Document modeling assumptions, boundary conditions, validation results, and recommendations.
• Develop scripts and tools for pre/post-processing of simulation data.

Skills

CFD

Heat transfer modeling

Mechanical stress/strain analysis

Independent work

Cross-functional communication

Education

B.S. or higher in Mechanical Engineering or related field

Tools

ANSYS (Mechanical, Maxwell, ROCKY, Fluent)

COMSOL Multiphysics

Python

MATLAB

Job description

Job DescriptionJob Description

Vulcan Elements is manufacturing American rare-earth permanent magnets for a secure, resilient future. With a focus on security and economic resiliency, we serve critical industries such as defense, aerospace, and automotive powering a high-technology future. Vulcan Elements is building a team of ambitious professionals committed to Mission Focus, Technical Excellence and Transparency.

As a Materials and Process Engineer with a metals focus, you will build and validate computational models of fluid dynamics, heat transfer, electromagnetic behavior, and mechanical response across key process steps, providing engineering insight that drives process optimization and supports product development. This is a technical role requiring strong fundamentals in computational mechanics, experience with commercial simulation platforms, and the ability to translate modeling results into actionable manufacturing guidance. This role begins in Durham, NC and is expected to move to Benson, NC upon completion of new facility.

Responsibilities

• Model thermal conditions during manufacturing processes such as sintering, heat treatment, and casting.
• Create representative models for various manufacturing processes including fluid dynamics, mechanical behavior, heat transfer, and electromagnetic phenomena.
• Use models combined with process data to support process improvement and optimization.
• Build and refine simulations using ANSYS (Mechanical, Maxwell, ROCKY, Fluent), COMSOL Multiphysics, or equivalent commercial simulation platforms.
• Collaborate with process, materials, and data engineers to integrate simulation outputs into process development and optimization workflows.
• Design simulation studies to evaluate process sensitivities, identify failure modes, and guide experimental campaigns.
• Document modeling assumptions, boundary conditions, validation results, and recommendations in a structured manner consistent with quality system requirements.
• Support development of custom scripts and automation tools (Python, MATLAB, or similar) for pre/post-processing of simulation data.

Responsibilities and tasks outlined are not exhaustive and may change as determined by the needs of the business.

Qualifications

• B.S. or higher in Mechanical Engineering, Aerospace Engineering, Materials Science and Engineering, or a closely related field.
• Demonstrated experience building and validating process models using ANSYS (e.g., Mechanical, Maxwell, ROCKY, Fluent), COMSOL Multiphysics, or equivalent commercial simulation software.
• Strong working knowledge of computational fluid dynamics (CFD), heat transfer modeling, and mechanical stress/strain analysis.
• Proficiency with scripting (Python, MATLAB, or similar) for simulation setup, data extraction, and post-processing.
• Ability to work independently, manage multiple concurrent modeling efforts, and communicate results clearly to cross-functional teams.

Must be a U.S. Person due to required access to U.S. export-controlled information or facilities.

Qualifications

• Experience modeling metal manufacturing processes such as sintering, casting, powder compaction, forging, or heat treatment.
• Experience modeling particle-level interactions including powder packing, granular flow, or discrete element methods (DEM).
• Experience with electromagnetic modeling and simulation (e.g., ANSYS Maxwell) for magnetic field analysis or electromagnetic process design.
• Familiarity with phase-field, CALPHAD, or other microstructure-evolution modeling approaches.
• Experience with Multiphysics coupled simulations (e.g., thermo-mechanical, fluid-structure interaction).
• Familiarity with GPU-accelerated computing, HPC environments, or cloud-based simulation platforms.
• Experience in a production, industrial, or R&D environment with exposure to manufacturing constraints and process validation.

Physical and Environmental Requirements

The position requires regular presence on the production floor and the ability to navigate all areas of the facility. Candidates must be able to climb stairs, stand and walk for extended periods, and work in environments that may be hot, humid, or noisy. The role also requires the use of personal protective equipment, including respirators, and adherence to all applicable safety policies, procedures, and regulatory requirements. Employees must be able to complete required fit testing, wear appropriate PPE for the duration of assigned tasks, and respond safely to changing conditions within the production environment.

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