Senior Machining Process Engineer – R&D

Vulcan Elements; North Carolina; On-site; USD 85,000 - 115,000; Full time

Job summary

Vulcan Elements in North Carolina is seeking a hands-on Machining Process Engineer to own and optimize the machining and finishing steps that convert magnet blocks into coating-ready parts. You will evaluate pathways, including slicing, grinding, tumbling, and other processes, with a focus on yield, tolerance, and production handoff.

The ideal candidate has 5+ years in machining/finishing, experience with hard/brittle materials, and the ability to design tooling and fixtures.

Qualifications

• B.S. in Mechanical Engineering or related field required.
• 5+ years of process engineering experience in machining/finishing.
• Ownership of a machining process from development to production release.
• Experience with NdFeB or magnet materials is a strong plus.

Responsibilities

• Own machining and finishing process KPIs and optimization.
• Evaluate, specify, and justify new machining processes; run vendor trials.
• Document developed processes and hand off to pilot production.
• Quantify yield vs throughput for varying magnet geometries.
• Develop tooling and fixturing; assess surface effects on coatings.

Skills

Abrasive Machining

Diamond Tooling

Machine Craft

Coolant & Filtration

DOE & Statistics

GD&T Metrology

CAD & Fixture Design

Education

B.S. in Mechanical Engineering or related field

Tools

SolidWorks

Fusion 360

Job description

Vulcan Elements is manufacturing American rare-earth permanent magnets for a secure, resilient future. With a focus on national security and economic resiliency, we serve critical industries such as defense, aerospace, and automotive powering a high‑technology future. Vulcan Elements is building a team of ambitious professionals committed to Mission Focus, Technical Excellence and Transparency.

Sintered NdFeB magnets are a challenge to machine and finish: hard, brittle, chip‑prone, corrosion‑sensitive. As a Machining Process Engineer you will own the key performance indicators for machining and finishing processes that turn sintered magnet blocks into finished coating‑ready parts. You will evaluate and optimize machining pathways, including wire sawing, precision grinding, tumbling, and other processes.

The ideal candidate is a hands‑on abrasive machining expert who can also make a detailed and quantitative process flow diagram. You will improve existing machining methods, including slicing, grinding, chamfering, and surface prep. You will select and qualify new shaping processes from lab‑scale development to validated, documented production handoff.

Responsibilities and tasks outlined are not exhaustive and may change as determined by the needs of the business.

Responsibilities

Process Characterization, Metrology & Quality

• Metrology, surface finish, and inspection methods
• Establish SPC and capability baselines and drive loss/defect rates down with data

Equipment Specification & New Process Introduction (NPI)

• Evaluate, specify, and justify new machining and finishing processes to Vulcan; run vendor trials, define acceptance criteria.
• Document developed processes and hand off validated, capable processes to pilot production— including processes destined for future high‑volume magnet factory programs.

Optimization of Existing Machining Processes

• Develop and optimize slicing, grinding, abrasive, tumbling processes
• Minimize loss and maximize material yield while holding thickness tolerance, TTV, bow, and warp targets; quantify the yield‑vs‑throughput trade space for varying magnet geometries.
• Development of novel tooling and fixturing as needed
• Understand and quantify surface effects on downstream coating adhesion, corrosion, and magnetic performance.

Desired Skills

• Abrasive Machining of Hard/Brittle Materials: Direct experience machining sintered magnets, technical ceramics, carbide, glass, silicon/semiconductor wafers, or similar brittle materials.
• Diamond Tooling: Working knowledge of diamond wire, wheel, and media specification.
• Machine Craft: Comfortable at the machine: setup, alignment, fixturing, troubleshooting vibration and chatter.
• Coolant & Filtration Systems: Practical understanding of coolant chemistry, delivery, filtration technologies, and swarf/sludge handling.
• Statistics & DOE: Fluency in designed experiments, measurement system analysis, SPC, and capability studies.
• Metrology & GD&T: Strong command of GD&T interpretation and precision dimensional/surface metrology at micron scale.
• CAD & Fixture Design: Able to design and iterate workholding, carriers, and handling fixtures (SolidWorks, Fusion 360, or similar).

Qualifications

• B.S. in Mechanical Engineering, Manufacturing Engineering, Materials Science, or equivalent hands‑on experience.
• 5+ years of process engineering experience in machining/finishing.
• Demonstrated ownership of a machining process from development through production release.
• Experience with NdFeB or other permanent magnet materials is a strong plus, but we will gladly teach magnets to someone who deeply knows grinding.

Must be a U.S. Person due to required access to U.S. export‑controlled information or facilities.

As set forth in Vulcan Elements’s Equal Employment Opportunity policy, we do not discriminate on the basis of any protected group status under any applicable law.