Materials Process Engineer - Metals Research Triangle Park, NC

Vulcan Elements Inc.; North Carolina; On-site; USD 90,000 - 140,000; Full time

Job summary

Vulcan Elements Inc. is seeking a Materials and Process Engineer with a metals focus to build and validate computational models across key manufacturing steps in Durham, NC, with a plan to move to Benson, NC upon facility completion.

You will apply CFD, heat transfer, and electromagnetic modeling to optimize processes, collaborating with process, materials, and data engineers and using ANSYS or COMSOL to deliver actionable manufacturing insights.

Qualifications

• B.S. or higher in Mechanical Engineering, Aerospace Engineering, Materials Science and Engineering, or a closely related field.
• Experience building and validating process models using ANSYS, COMSOL Multiphysics, or equivalent software.
• Strong working knowledge of CFD, heat transfer modeling, and mechanical stress/strain analysis.
• Proficiency with scripting languages (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.

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.

Skills

CFD knowledge

Heat transfer modeling

Mechanical stress/strain analysis

Analytical thinking

Independent work

Cross-functional communication

Education

Bachelor's degree in Mechanical Engineering, Aerospace Engineering, Materials Science and Engineering or related field

Tools

ANSYS (Mechanical, Maxwell, ROCKY, Fluent)

COMSOL Multiphysics

Python

MATLAB

Job description

Vulcan Elements is manufacturing American rare-earth permanent magnets for a secure, resilient future. With a focus on national 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 languages (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.

Preferred 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.

As set forth in Vulcan Elements’s Equal Employment Opportunity policy, we do not discriminate on the basis of any protected group status under any applicable law.