Senior Machining Process Engineer – R&D

About the Role

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. 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. Sintered NdFeB magnets are hard, brittle, chip-prone, and corrosion-sensitive, presenting unique challenges in machining and finishing.

Responsibilities

• Process Characterization, Metrology & Quality: Establish metrology, surface finish, and inspection methods. Implement Statistical Process Control (SPC) and capability baselines to drive down loss and defect rates using data.
• Equipment Specification & New Process Introduction (NPI): Evaluate, specify, and justify new machining and finishing processes. Conduct vendor trials, define acceptance criteria, and document developed processes. Hand off validated, capable processes to pilot production, including those for future high-volume magnet factory programs.
• Optimization of Existing Machining Processes: Develop and optimize slicing, grinding, abrasive, and tumbling processes. Minimize loss and maximize material yield while maintaining thickness tolerance, TTV, bow, and warp targets. Quantify the yield-vs-throughput trade space for varying magnet geometries.
• Develop novel tooling and fixturing as needed.
• Understand and quantify surface effects on downstream coating adhesion, corrosion, and magnetic performance.

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

Requirements

• 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.

Desired Skills

• Experience in semiconductor wafering, optics fabrication, cutting tool manufacturing, or technical ceramics.

Laboratory Safety and PPE Requirements

This role requires strict adherence to all laboratory safety protocols and regulatory guidelines. Employees must consistently wear appropriate personal protective equipment (PPE), including lab coats, safety glasses, gloves, and any additional gear required for specific materials or processes.

• The position involves working around equipment and procedures that present cut hazards and other physical risks associated with slicing, grinding, and tumbling operations.
• Team members must follow all established safety rules, use tools and machinery only as trained, and maintain awareness of mechanical pinch points, sharp components, and moving parts.
• Employees are expected to maintain a clean and compliant work area, promptly report any unsafe conditions, and complete all required safety training.

A strong commitment to maintaining a safe and compliant laboratory environment is essential for success in this role.