Modeling and Simulation Manager

About the Role

Vulcan Elements is manufacturing American rare-earth permanent magnets for a secure, resilient future, serving critical industries such as defense, aerospace, and automotive. As the Modeling and Simulation Manager, you will grow and lead a multidisciplinary team of computational scientists and engineers, driving physics-based and data-based modeling efforts to improve magnet performance, production yields, and process efficiency. This hands-on technical leadership role involves both direct contributions to modeling work and team development across modalities like mechanical, fluid dynamics, electronic structure, and mathematical/image analysis. Your team’s output will shape process decisions, reduce experimental cycles, and create quantitative links between structure, processing, and final properties. The role initially supports pilot-scale and R&D activities (RTP, NC) with potential expansion to commercial plant operations (Benson, NC).

Responsibilities

• Build and manage a matrixed modeling and simulations team with expertise spanning Finite Element Analysis (FEA), Computational Fluid Dynamics (CFD), stress/strain analysis, thermodynamic modeling, mathematical/image analysis, and Density Functional Theory (DFT); define hiring roadmap, team structure, and capability milestones.
• Translate R&D priorities into a modeling agenda with clear deliverables, timelines, and success criteria in partnership with process engineering, materials science, and production teams.
• Foster a culture of scientific rigor, reproducibility, and rapid iteration; establish standards for model validation, documentation, and peer review.
• Present results and recommendations to technical and executive stakeholders; communicate uncertainty and model limitations clearly.
• Responsibilities may evolve based on business needs.

Qualifications

• Ph.D. or M.S. in Materials Science, Chemical Engineering, Mechanical Engineering, Applied Physics, or a related quantitative field.
• 5+ years of hands-on experience with COMSOL, Fluent, or equivalent; demonstrated ability to build and validate coupled multiphysics models and FEA.
• Strong mathematical modeling background; experience with image analysis, machine learning, statistical modeling, or signal processing applied to materials characterization data.
• Familiarity with rare earth magnets, NdFeB alloy systems, or related metallic/magnetic materials.
• Experience leading or mentoring a small technical team; ability to set priorities, provide technical guidance, and develop junior researchers.
• Proficiency in Python, MATLAB, Git, or equivalents for scripting, data analysis, and model post-processing.
• Strong written and verbal communication skills; ability to produce clear technical reports and present complex results to non-specialist audiences.
• Must be a U.S. Person due to required access to U.S. export-controlled information or facilities.

Preferred Qualifications

• Direct experience with DFT codes (VASP, Quantum ESPRESSO, or similar) or demonstrated ability to direct and interpret DFT studies.
• Background in rare earth processing, hydrometallurgy, or magnet manufacturing.
• Experience with grain boundary diffusion processes or sintering simulation.
• Familiarity with thermodynamic modeling and databases such as FactSage or ThermoCalc.
• Knowledge of machine learning principles for data analysis.
• Familiarity with electron microscopy image analysis (SEM/EDS/EBSD) and quantitative microstructural characterization.
• Publication record in computational materials science, process simulation, or permanent magnets.
• Experience managing budgets, external collaborators, or academic partnerships.