Process Engineer - Powder Metallurgy

MP Materials; Fort Worth (TX); On-site; USD 70,000 - 110,000; Full time

Job summary

Join a forward-thinking company as a Process Engineer in Powder, where you will play a key role in building a cutting-edge manufacturing facility. This position offers a unique opportunity to shape the future of American manufacturing by developing advanced processes for metal powder production. You will collaborate with diverse teams, engage in innovative problem-solving, and ensure high-quality standards in production. If you are driven by challenges and eager to make a significant impact in a rapidly evolving industry, this role is perfect for you.

Qualifications

• 3-5 years experience in metal powder processing with industrial scale.
• Deep understanding of powder metallurgy processes and quality control.

Responsibilities

• Coordinate with production teams to execute customer products.
• Plan and assist with process development for powder production.
• Monitor quality control procedures for efficient operations.

Skills

Problem-solving

Communication Skills

Process Control

Quality Control

Education

BS degree in Metallurgy/Materials Science

Mechanical, Chemical Engineering, or Chemistry

Tools

SAP

Microsoft Office

AutoCAD/Solidworks

Python

MATLAB

Mini-Tab

Job description

Company Overview:

MP Materials (NYSE: MP) is on a mission to restore the full rare earth supply chain to the United States of America. From electric cars to wind turbines and drones, rare earths are essential to the low-carbon, electrified technologies that power modern life. We hire ambitious, mission-driven people motivated to solve problems and affect change. Our values are grounded in teamwork, resiliency, and integrity, with an enduring commitment to our employees, community, and the environment. In the coming years, MP Materials will grow from a core materials and chemical processing company into a large industrial manufacturer. Our employees will lead this exciting transformation and grow professionally with us.

Position Overview:

The Process Engineer – Powder will be an integral part of the team designing and building a new metal, alloy, and magnet-making facility. This is a rare opportunity to have a central role in the development of a greenfield advanced manufacturing facility and helping to define the future of American manufacturing. The ideal candidate will have hands-on experience in controlling metal powder production processes such as powder conveyance, hydrogen decrepitation, jet milling, classification, blending, quality control and other related powder processing techniques. The Process Engineer must be comfortable with equipment fault diagnosis, process development, PLCs, and P&ID. This position reports into a Senior Engineering Manager.

The new facility will contain a broad range of chemical, mechanical, and thermal processes, including electrowinning, strip casting, powder production, pressing & sintering, machining, and assembly. Because of the broad range of processes in use, it is important that the Process Engineer be able to engage with a broad range of technical specialists and gain a working understanding of the physical processes, key control metrics, and potential hazards involved. The key aspect of this role is to provide technical coordination and support to the powder processing operation to meet customer requirements.

Position Responsibilities:

• Member of the Production Engineering team. Work with production team members of upstream and downstream processes to execute the products for customers.
• Work with procurement, vendors, maintenance, operators, and other team members on equipment specification, design reviews, and commissioning of new plant.
• Contribute to EHS risk assessments, HAZOP studies, and regulatory compliance.
• Plan, execute, and assist with process and procedure development for hydrogen decrepitation (HD) furnace, jet milling, dry grinding, and powder blending.
• Work closely with the NPI team in new process development and deployment in industrial scale.
• Provide technical training and support to the production team and technicians on process knowledge.
• Evaluate customer requirements and work in partnership with broader manufacturing and engineering teams to define process control plans to meet customer specifications.
• Monitor and direct changes to key operating parameters under area of responsibility driving to achieve high yield, consistent product quality, and minimal EHS impacts.
• Supervise the daily use of quality control procedures, driving initiatives to ensure stable and efficient powder processing operations.
• Investigate and resolve equipment and quality issues within HD furnace, jet milling and subprocesses, working with QA, production, and customer service to address any product quality or customer complaints.
• Document and disclose intellectual property and assist in patent filing preparation and defense.
• Other duties, as assigned.

Basic Qualifications:

• BS degree in Metallurgy/Materials Science, Mechanical, Chemical Engineering, Chemistry, or related field.
• 3-5 years’ experience in metal powder processing with industrial scale processes and equipment.
• Deep understanding of powder metallurgy processes for part manufacturing and powder quality control fundamentals such as particle size distribution (PSD), particle flowability, particle agglomeration, and more.
• Knowledge and experience in gathering and tracking process control information for SPC.
• Problem-solving experience (FMEA, 8D, A3, Root Cause Analysis etc.).
• Excellent written and verbal communication skills.
• Experienced user of Microsoft Office suite.
• Valid Driver’s License and good driving record are required to drive company vehicles on property.

Desired Qualifications:

• 5+ years of industrial experience in powder manufacturing, processing, and/or conducting powder metallurgy processes.
• Deep technical knowledge of metal powder pulverization and hydrogen furnace operation.
• Practical experience of the process safety associated with metal powder processing.
• Experience with SAP.
• Ability to identify and solve problems and convince others (management down to operators) that your solution is the right one.
• Experience with programming and process control operations; P&ID, PLC, CFD, MATLAB, Python, Mini-Tab, AutoCAD/Solidworks.