Senior Machining Process Engineer – R&D

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

Requirements

• Absorbate 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