Senior Engineer, Metal Making

MP Materials Corp.; Fort Worth (TX); On-site; USD 100,000 - 130,000; Full time

Job summary

A leading U.S. materials manufacturer is seeking a hands-on Senior Engineer to lead the development of advanced technologies for producing high-purity rare earth metal and alloys. This position involves scaling electrometallurgical technologies and emphasizes collaboration with cross-functional teams. Candidates must possess a Ph.D. in a related field and have significant experience with molten salt electrolysis processes. Join this innovative company to restore strategic manufacturing capabilities in the U.S. Competitive compensation and growth opportunities are offered.

Qualifications

• 3+ years of hands-on experience with molten salt electrolysis and/or metallothermic reduction processes.
• Agile researcher, adept at identifying untested questions about materials and processes.
• Experience leading technical development projects, with the ability to prioritize multiple projects.

Responsibilities

• Lead the development and optimization of rare earth metal and alloy production processes.
• Translate lab findings into scalable, production-ready processes.
• Document all projects and provide written guidance for model usage.

Skills

Expertise in extractive metallurgy

Hands-on experience with molten salt electrolysis

Strong theoretical and experimental background in electrochemistry

Excellent written and verbal communication skills

Education

Ph.D. in Materials Science & Engineering or related field

Tools

Electrochemical instrumentation

Thermodynamic modeling software (FactSage)

Job description

If you are unable to complete this application due to a disability, contact this employer to ask for an accommodation or an alternative application process.

Fort Worth, TX, US

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 Senior Engineer to lead the development of advanced technologies for producing high‑purity rare earth metal and alloys, critical for high‑performance permanent magnets. This role focuses on developing and scaling electrometallurgical and pyrometallurgical technologies – including but not limited to molten salt electrolysis and metallothermic reduction. The ideal candidate will bring deep expertise in extractive metallurgy, and apply a combination of experimental research, process modeling, and material science expertise to design, optimize, and scale metal making pathways. This position will play a pivotal role in restoring strategic manufacturing capabilities to the U.S.

Position Responsibilities:

• Lead the development and optimization of rare earth metal and alloy production processes.
• Design and execute laboratory and pilot‑scale experiments involving high‑temperature reaction kinetics, molten salt systems, and reduction pathways.
• Apply simulation tools to model the thermodynamics, transport phenomena, and electrochemical behavior in rare earth metal extraction and refining.
• Translate lab and pilot‑scale findings into scalable, production‑ready processes.
• Collaborate cross‑functionally with R&D, manufacturing, and quality teams to align process development with operational goals.
• Characterize materials using techniques such as XRD, XRF, LECO, and SEM.
• Utilize electrochemical instrumentation (e.g., galvanostats, potentiostats) and techniques (e.g., cyclic voltammetry, impedance spectroscopy) to tune and evaluate processes.
• Document all projects, provide written guidance for model usage, and build team knowledge of current and future rare earth research.
• Work closely with EHS to ensure that all work is done to ensure world‑class health and safety, and full compliance with relevant environmental regulations.
• Engage with university researchers, strategic partners, and government laboratories involved in rare earth reduction research to bring value and knowledge to MP Materials.
• Other duties as assigned.

Basic Qualifications:

• Ph.D. in Materials Science & Engineering, Metallurgy, Chemical Engineering, Electrochemistry, or related field.
• 3+ years of hands‑on experience with molten salt electrolysis and/or metallothermic reduction processes.
• Experience with electrochemical instrumentation and techniques.
• Strong theoretical and experimental background in electrochemistry, transport phenomena, thermodynamics, and kinetics.
• Agile researcher, adept at identifying untested questions about materials and processes.
• Excellent written and verbal communication skills.

Desired Qualities:

• Experience building furnace reactors, electrolysis cells, and custom experimental setups for electrometallurgy and/or pyrometallurgy processes.
• Experience with rare earth metal, alloy, and/or magnet making processes.
• Experience leading technical development projects, with the ability to prioritize and manage multiple concurrent projects.
• Experience with thermodynamic modeling software such as FactSage and simulation tools such as finite element analysis and computational fluid dynamics.
• Experience with programming, and the ability to apply those skills to automate routine analysis, data management, and process control operations.
• Lifelong learner able and enthusiastic to apply existing skills and experiences to new problems.

MP Materials is Proud to be an Equal Opportunity / Affirmative Action Employer

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.

For Assistance with Application

Alternative methods of applying for employment are available to individuals unable to submit an application through this site because of a disability. Contact Human Resources Department at 702‑844‑6111; dial 7 when prompted for HR; 1700 South Pavilion Center Dr. 8th Floor, Las Vegas, NV 89135 to discuss reasonable accommodation.