R&D Engineer

USA Rare Earth, Inc. (Nasdaq: USAR); Wheat Ridge (CO); On-site; USD 105,000 - 120,000; Full time

Job summary

USA Rare Earth, Inc. in Wheat Ridge, Colorado is seeking an R&D Engineer to support the development and scaling up of rare earth processing technologies. The role involves hands-on activities bridging lab research and pilot plant operations to advance innovative processes.

The ideal candidate will possess a Bachelor's degree in Chemical, Metallurgical or Materials Engineering and have 3 to 7 years of relevant experience, focusing on extraction, separation, and purification methodologies.

This position comes with a competitive salary range of $105,000 to $120,000 per year, reflecting our commitment to attracting top talent.

Qualifications

• 3–7 years of experience in hydrometallurgy, chemical processing, or process R&D.
• Experience with pilot plant operations and process scale-up.
• Familiarity with rare earth separation techniques preferred.

Responsibilities

• Design and execute experiments for rare earth leaching and purification.
• Translate bench-scale work into pilot-scale operations.
• Operate and support pilot plant systems for testing and data collection.

Skills

Hydrometallurgy

Data analysis

Problem-solving

Process troubleshooting

Communication skills

Education

Bachelor’s degree in Chemical, Metallurgical, or Materials Engineering

Tools

PFDs/P&IDs

Process control systems (SCADA/DCS)

Job description

Who We Are

We are on a mission to become a leading supplier of critical materials that enable the green energy and technology revolution. Our materials and technologies are required for the electric vehicle, green energy, consumer electronics, and defense industries, and our battery grade lithium and tech metals are needed for chipsets, semiconductors, and 5G. We have a substantial interest in the Round Top, Heavy Rare Earth, Lithium and Critical Minerals deposit in West Texas. We have also developed the United States’ first rare earth and critical minerals processing facility and we own the only scalable, sintered neo‑magnet manufacturing system in the Western Hemisphere. By developing this fully integrated, US‑based mine‑to‑magnet critical mineral supply chain, we are poised to become the leading domestic supplier to these industries.

What You Can Expect

• Build Solutions – If our task was a simple one, it would already be done. We are creative and solution‑oriented, and we think outside the box to solve important problems. We know that a range of expertise and technologies is needed for success, and we work across sectors and alongside customers to deliver world‑class solutions in sustainable ways.
• Deliver Quality – When we do things, we do them well. We believe that top‑tier quality leads to industry competitiveness and we hold ourselves to the highest quality standards. We move fast when executing, but safety, quality, and excellence always come first.
• Lead responsibly – We have a responsibility to the planet, our consumers, our country, and each other. We put safety at the center of all we do, take accountability for our actions, incorporate sustainable practices in our processes and act with the financial best interest of our investors and consumers in mind.
• Win Together – Establishing a rare earth magnet supply chain is a big undertaking – and getting there is a team effort. We communicate openly, work together and challenge each other in pursuit of our goals. With every step we take we learn and get better.

Position Overview

The R&D Engineer supports the development and scale‑up of rare earth processing technologies, focusing on extraction, separation, and purification from primary and recycled feedstocks. This role is highly hands‑on, bridging lab research and pilot plant operations to advance processes toward commercial readiness.

Key Responsibilities

• Design and execute experiments for rare earth leaching, solvent extraction, and purification.
• Translate bench‑scale work into pilot‑scale operations, supporting scale‑up and process optimization.
• Operate and support pilot plant systems, including test planning, data collection, and troubleshooting.
• Perform mass balances and analyze process data to improve recoveries, efficiency, and product quality.
• Develop technical documentation (SOPs, PFDs, test reports) to support pilot operations and scale‑up.
• Collaborate with engineering and operations teams to advance process design and commercialization.
• Support safety programs, including PHAs and compliance with environmental and operational standards.
• Coordinate with external partners (EPCMs, vendors, labs) as needed.

Qualifications

• Bachelor’s degree in Chemical, Metallurgical, or Materials Engineering (advanced degree a plus).
• 3–7 years of experience in hydrometallurgy, chemical processing, or process R&D.
• Experience with pilot plant operations and process scale‑up.
• Familiarity with rare earth separation techniques (e.g., solvent extraction, precipitation) preferred.
• Strong data analysis, problem‑solving, and process troubleshooting skills.
• Working knowledge of PFDs/P&IDs and process control systems (SCADA/DCS) is a plus.

Skills & Attributes

• Hands‑on, execution‑focused mindset suited for a pilot‑stage environment.
• Ability to manage multiple priorities and adapt in a fast‑paced setting.
• Strong communication skills and attention to detail.
• Commitment to safety, quality, and continuous improvement.

Physical Demands

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions. Specific vision abilities required by this job include close vision and distance vision. While performing the duties of this job, the employee is regularly required to walk, stand, move, sit, carry, bend, kneel, reach, push, pull, lift, use hands and fingers, handle, or feel, and talk and hear. May be required to lift and move boxes or packages not exceeding 20 pounds in weight. Some work stress inherent to the position and extended work hours may be required.

Work Environment

The work environment will be an office environment. Noise level: Normal office noises. The above statements are intended to describe the general nature and level of work being performed by people assigned to this job. They are not intended to be an exhaustive list of all responsibilities, duties, or skills required of personnel so classified. Reporting relationships may not reflect the most recent changes to the organization.

Equal Employment Opportunities

USA Rare Earth proudly supports Equal Employment Opportunities. USA Rare Earth's policy is to provide equal employment opportunities to all applicants and will provide reasonable accommodations according to applicable federal, state, and/or local laws. For assistance applying for employment through this site due to disability, please contact People & Culture, [e-mail], to discuss reasonable accommodations.

Pay Range

105,000 - 120,000 USD per year (Wheat Ridge, CO)