Senior Materials & Process Engineer - Powder Metallurgy

About the role

As a Senior/Staff Materials and Process Engineer, you will serve as the technical lead for the end-to-end powder metallurgy manufacturing process—spanning powder processing, advanced compaction, and thermal treatment. You will optimize current production lines, scale new NdFeB magnet formulations, and troubleshoot complex materials anomalies. This role bridges the gap between R&D and high-volume production, ensuring maximum magnetic performance, microstructural integrity, and manufacturing yield. This is a high-impact, high-ownership role requiring deep technical expertise and leadership.

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 the Manufacturing team for selection and commissioning of next-generation manufacturing equipment.

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

Qualifications

• Bachelor’s, Master’s, or Ph.D. in Materials Science, Metallurgical Engineering, Chemical Engineering, or a related technical discipline.
• 8+ years of hands-on engineering experience in powder metallurgy processing (industrial manufacturing setting preferred).
• Experience with reactive metal powder processing, protective inert atmospheres, vacuum thermal processing, and advanced sintering kinetics.
• Experience with materials characterization and analytical techniques such as SEM, XRD, TGA/DSC.
• Strong experience in design of experiments, statistical processing, and leading research efforts.
• Must be a U.S. Person due to required access to U.S. export-controlled information or facilities.

Preferred Qualifications

• Direct experience in the manufacturing of sintered NdFeB permanent magnets and grain boundary diffusion processes.
• Strong proficiency in evaluating magnetic materials properties and interpreting microstructural data.
• Experience utilizing data analysis tools (such as Python, MATLAB, or JMP) to analyze manufacturing quality datasets or automate performance mapping.
• Familiarity with ISO 9001 or IATF 16949 quality management standards.

Physical and Environmental Requirements

• Regular presence on the production floor and the ability to navigate all areas of the facility.
• Ability to climb stairs, stand and walk for extended periods, and work in environments that may be hot, humid, or noisy.
• Use of personal protective equipment, including respirators, and adherence to all applicable safety policies, procedures, and regulatory requirements.
• Ability to complete required fit testing, wear appropriate PPE for the duration of assigned tasks, and respond safely to changing conditions within the production environment.