Process Engineer, Metal Making

MP Materials; Fort Worth (TX); On-site; USD 85,000 - 120,000; Full time

Job summary

MP Materials is seeking a hands-on process engineer to design, build, and operate a new metal, alloy, and magnet-making facility. You’ll support molten salt electrolysis and strip casting, producing on-spec metal and flake while improving daily operations.

You will collaborate with QAQC, EHS, supply chain, and maintenance to meet area objectives and drive continuous improvement across the plant.

Qualifications

• BS degree in metallurgy/materials science or chemical/ mechanical engineering.
• 2+ years’ experience with industrial-scale processes and equipment.
• Experience gathering and tracking process control information for SPC.

Responsibilities

• Participate in equipment specification, design reviews, and commissioning of electrolysis cells and strip casters.
• Lead operators and technicians through technical training and support.
• Contribute to EHS risk assessments, HAZOP studies, and regulatory compliance.
• Evaluate raw materials and their impact on plant performance and product quality.
• Track KPIs to achieve high yield, consistent product quality, and minimal EHS impacts.
• Supervise the daily use of quality control procedures.
• Investigate and resolve quality issues within molten salt electrolysis and strip casting.
• Lead continuous improvement activities to eliminate waste and reduce overall cost.

Skills

Industrial processes

SPC

Data analysis

Communication

Microsoft Office

Problem solving

Education

BS in Metallurgy/Materials Science/ CHEM ENG

Tools

SAP

COMSOL Multiphysics

CFD

MATLAB

Python

Minitab

AutoCAD

SolidWorks

Job description

Company Overview

MP Materials (NYSE: MP) is rebuilding American industrial capability for a new era of autonomy, robotics, and electrification. We are the only U.S. company with a fully integrated rare‑earth supply chain—from mining and refining to advanced metal and magnet manufacturing. Our products include both the critical materials used to make permanent magnets and the finished magnets themselves—enabling next‑generation technologies in robotics, automation, aerospace, transportation, defense, and energy systems. These materials are the foundation of physical AI—the convergence of computation, movement, and control. We hire ambitious, mission‑driven people who want to tackle complex challenges and shape the future of strategic industries. Our culture is rooted in teamwork, resiliency, and integrity, with a deep commitment to operational excellence and national purpose. MP is rapidly evolving from a materials producer into a leading U.S. manufacturer—and our people are driving that transformation.

Position Overview

MP Materials is seeking a hands‑on process engineer to be an integral part of the team designing, building, and operating a new metal, alloy, and magnet‑making facility. This role will support the first and second steps in our manufacturing process: molten salt electrolysis and strip casting. It will be responsible for producing on‑spec metal and flake while improving daily operations and will work closely with QAQC, EHS, supply chain, and maintenance teams to meet area objectives.

Position Responsibilities

• Participate in equipment specification, design reviews, and commissioning of electrolysis cells and strip casters.
• Lead operators and technicians through technical training and support.
• Contribute to EHS risk assessments, HAZOP studies, and regulatory compliance.
• Evaluate raw materials and their impact on plant performance and product quality.
• Track KPIs to achieve high yield, consistent product quality, and minimal EHS impacts.
• Supervise the daily use of quality control procedures.
• Investigate and resolve quality issues within molten salt electrolysis and strip casting.
• Lead continuous improvement activities to eliminate waste and reduce overall cost.
• Communicate progress verbally and through detailed written technical reports and presentations.
• Document and disclose intellectual property and assist in patent filing preparation and defense.
• Work with procurement, vendors, maintenance, operators, and other team members to support production and operational objectives.
• Other duties as assigned.

Basic Qualifications

• BS degree in Metallurgy/Materials Science, Chemical Engineering, Mechanical Engineering, or related field.
• 2+ years’ experience with industrial-scale processes and equipment.
• Knowledge and experience in gathering and tracking process control information for SPC.
• Problem‑solving experience, including FMEA, 8D, A3, and root‑cause analysis.
• Excellent written and verbal communication skills.
• Strong data analysis and hands‑on engineering skills.
• Experienced user of Microsoft Office suite.

Desired Qualities

• Advanced degree in Metallurgy/Materials Science, Chemical Engineering, Chemistry, or related field.
• Deep technical knowledge of high‑temperature metallurgy and/or molten salt electrolysis.
• Experience with SAP.
• Ability to identify and solve problems and influence stakeholders, from management to operators, to adopt effective solutions.
• Experience with programming and process‑control operations; experience with COMSOL Multiphysics, CFD, MATLAB, Python, Minitab, AutoCAD, and/or SolidWorks.

MP Materials is proud to be an Equal Opportunity/affirmative action employer. EEO is the law. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, protected veteran status, or any other characteristic protected by law. Underrepresented groups, women, disabled veterans are encouraged to apply. Candidates with disabilities that make them unable to meet the position’s requirements will still be considered qualified if they can perform the essential functions with reasonable accommodation.