Process Engineer - Powder Metallurgy

MP Materials; Fort Worth (TX); On-site; USD 110,000 - 150,000; Full time

Job summary

MP Materials is hiring a Process Engineer – Powder to design and build a new metal, alloy, and magnet-making facility in the U.S. The role focuses on powder production, quality control, and process development, requiring hands-on experience with powder processing techniques and equipment.

The engineer will work with a broad range of technical specialists, engage in PLCs and P&ID, and provide training to the production team while ensuring safety and regulatory compliance.

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.
• Knowledge of powder metallurgy processes and fundamentals (PSD, flowability, agglomeration).
• Experience gathering and tracking process control information for SPC.
• Strong problem-solving and communication skills.

Responsibilities

• Member of the Production Engineering team and collaborate with upstream/downstream teams to execute products.
• Coordinate with procurement, vendors, maintenance, and operators on equipment specs, design reviews, and commissioning.
• Contribute to EHS risk assessments, HAZOP studies, and regulatory compliance.
• Develop and implement process and procedures for hydrogen decrepitation, jet milling, dry grinding, and blending.
• Support NPI development and deployment of processes at industrial scale.
• Provide technical training and support on process knowledge to production staff.
• Define process control plans to meet customer specifications and drive yield and quality improvements.
• Supervise quality control procedures to ensure stable powder processing operations.
• Investigate and resolve equipment/quality issues with QA, production, and customer service.

Skills

Communication skills

Problem solving

Attention to detail

Education

Bachelor's degree in Metallurgy/Materials Science or related field

Tools

P&ID

PLC

AutoCAD/SolidWorks

MATLAB

Python

MiniTab

CFD

SAP

MS Office

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

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.
• Monitors and directs 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 experience of industrial experience 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.

MP Materials is Proud to be an Equal Opportunity /

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 whose disabilities make them unable to meet the position’s requirements will still be considered qualified if they can perform the essential functions of the job with reasonable accommodation.

Your Right to Work

In compliance with federal law, all persons hired will be required to verify identity and eligibility to work in the United States and to complete the required employment verification document form upon hire.