Senior Engineer, Metal Making

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

Job summary

A leading materials company in Fort Worth, TX is seeking a hands-on Senior Engineer to develop advanced technologies for high-purity rare earth metals. This role involves leading the optimization of production processes and executing experiments in molten salt electrolysis. The ideal candidate must have a Ph.D. and experience in electrochemical techniques. Join us in restoring strategic manufacturing capabilities in the U.S., while collaborating with cross-functional teams to align development with operational goals.

Qualifications

• 3+ years of experience with molten salt electrolysis or metallothermic reduction.
• Strong theoretical and experimental electrochemical background.
• Excellent communication skills, both written and verbal.

Responsibilities

• Lead development and optimization of rare earth metal production processes.
• Execute laboratory and pilot-scale experiments.
• Translate findings into production-ready processes.

Skills

Electrochemistry

Transport phenomena

Thermodynamics

Kinetics

Experimental research

Education

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

Tools

Electrochemical instrumentation

Finite element analysis software

Computational fluid dynamics

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 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 / Affidavit (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.