Senior NdFeB Powder Metallurgy Engineer

Vulcan Elements; North Carolina; On-site; USD 140,000 - 200,000; Full time

Job summary

Vulcan Elements is seeking a Senior/Staff Materials and Process Engineer to lead the end-to-end powder metallurgy manufacturing process. You will optimize current production lines, scale new NdFeB magnet formulations, and troubleshoot complex material anomalies, bridging R&D and high-volume production for maximum magnetic performance and yield.

This high-ownership role requires deep technical expertise, leadership, and the ability to drive process improvements across hydrogen decrepitation, jet

Qualifications

• Bachelor’s, Master’s, or Ph.D. in Materials Science, Metallurgical Engineering, Chemical Engineering, or related discipline.
• 8+ years hands-on powder metallurgy experience in industrial manufacturing.
• Experience with reactive metal powder processing, protective inert atmospheres, vacuum thermal processing, and advanced sintering kinetics.
• Experience with materials characterization techniques (SEM, XRD, TGA/DSC).

Responsibilities

• Own and optimize the powder metallurgy pipeline, including hydrogen decrepitation, jet milling, pressing and compaction, vacuum sintering, and post-sinter heat treatments.
• Correlate process variables to magnetic properties, microstructure, and part quality.
• Lead root‑cause failure analyses for sample defects and implement corrective actions.
• Transition new alloy compositions from pilot scale to robust, high‑volume production.
• Define technical specifications and partner with Manufacturing team for selection and commissioning of next‑generation manufacturing equipment.

Skills

Leadership

Project management

Analytical thinking

Communication

Problem solving

Education

Bachelor’s/Master’s/PhD in Materials Science or related

Advanced degree in Metallurgical/Chemical Engineering

Tools

SEM

XRD

TGA/DSC

Python

MATLAB

Job description

Vulcan Elements is seeking a Senior/Staff Materials and Process Engineer to lead the end-to-end powder metallurgy manufacturing process. You will optimize current production lines, scale new NdFeB magnet formulations, and troubleshoot complex material anomalies, bridging R&D and high-volume production for maximum magnetic performance and yield.

This high-ownership role requires deep technical expertise, leadership, and the ability to drive process improvements across hydrogen decrepitation, jet