NdFeB Magnet R&D & Process Engineer

Vulcan Elements; North Carolina; On-site; USD 90,000 - 130,000; Full time

Job summary

Vulcan Elements is seeking an experienced R&D Materials & Process Engineer to lead the development and scale-up of NdFeB magnet fabrication. You will bridge laboratory research and full-scale production, establishing processing windows and improving yield.

You will design experiments, optimize powder metallurgy steps, and work with production teams to implement robust tooling and processing improvements, ensuring high-quality magnets for defense, aerospace, and automotive applications.

Qualifications

• Bachelor's degree in Materials Science, Metallurgical Engineering, Physics, or Process Engineering.
• 3+ years in process engineering or industrial R&D.
• Deep practical knowledge of powder metallurgy, vacuum thermal processing, and metal powder pressing.
• Hands-on experience operating, troubleshooting, or optimizing industrial processing equipment.
• Strong proficiency with magnetic testing systems (Hysteresisgraph, Pulsed Field Magnetometry) and material characterization tools (SEM/EDS, XRD, particle size analyzers).
• Proven track record applying DOE, Six Sigma methodologies, and statistical tools (e.g. Python, or JMP) for data analysis.

Responsibilities

• Design and refine core processing steps, including Strip Casting, Hydrogen Decrepitation, Jet Milling & press parameters as they relate to process throughput, yield, downstream processing and final magnetic properties.
• Develop and fine-tune vacuum sintering profiles/thermal cycles as they relate to microstructural features and final magnetic performance.
• Desing of Experiments for improvement in magnetic performance, process throughput and yield, and cost improvement.
• Conduct root-cause failure analysis (RCA) to eliminate processing defects.
• Support the scaling up of validated experimental processes from lab/pilot-scale equipment to full commercial production lines.
• Collaborate closely with production and equipment engineering teams to modify existing tooling or specify requirements for next-generation processing equipment.
• Responsibilities and tasks outlined are not exhaustive and may change as determined by the needs of the business.

Skills

DOE

Six Sigma

Statistical analysis

Metallurgy knowledge

Problem solving

Education

Bachelor's degree in Materials Science

Metallurgical Engineering

Physics

Process Engineering

Tools

Hysteresisgraph

Pulsed Field Magnetometry

SEM/EDS

XRD

Particle size analyzers

Python

JMP

Job description

Vulcan Elements is seeking an experienced R&D Materials & Process Engineer to lead the development and scale-up of NdFeB magnet fabrication. You will bridge laboratory research and full-scale production, establishing processing windows and improving yield.

You will design experiments, optimize powder metallurgy steps, and work with production teams to implement robust tooling and processing improvements, ensuring high-quality magnets for defense, aerospace, and automotive applications.