Powder Processing Engineer

1 week ago

Fort Worth, Texas, United States MP Materials Corp. Full time
Job Overview

MP Materials Corp. is dedicated to revitalizing the complete rare earth supply chain within the United States. Rare earth elements are crucial for the advancement of low-carbon technologies, including electric vehicles, renewable energy systems, and various modern applications. We seek driven individuals who are eager to tackle challenges and contribute to meaningful change. Our core values emphasize collaboration, resilience, and integrity, alongside a steadfast commitment to our workforce, community, and the environment.

The role of the Process Engineer – Powder is vital in the establishment of a new facility focused on metal, alloy, and magnet production. This position presents a unique opportunity to play a key role in the development of a state-of-the-art manufacturing site, shaping the future of production in America. The ideal candidate will possess practical experience in managing metal powder production processes, including but not limited to powder conveyance, milling, classification, blending, and quality control methodologies.

The Process Engineer will collaborate closely with the Production Engineering team, ensuring the smooth integration of powder production with both upstream and downstream operations. Upstream activities will encompass electrowinning, alloying, and strip casting, while downstream processes will involve pressing, sintering, and machining. It is essential for the Process Engineer to engage with a diverse array of technical experts to gain insights into the physical processes, critical control metrics, and potential risks associated with the entire manufacturing workflow.

Key Responsibilities:

  • Provide technical guidance and support to optimize powder processing operations in alignment with internal and customer standards.
  • Collaborate with production teams across upstream and downstream processes to ensure effective integration throughout the manufacturing operations.
  • Deliver technical training and assistance to production personnel.
  • Engage with procurement, vendors, maintenance teams, and operators regarding equipment specifications, design evaluations, and the commissioning of new facilities.
  • Contribute to EHS risk assessments, HAZOP studies, and compliance initiatives.
  • Plan and execute process and procedure development for hydrogen decrepitation (HD) furnaces, jet milling, and other powder processing techniques.
  • Work alongside the R&D team to facilitate new process innovations and expedite the implementation of advanced technologies at an industrial scale.
  • Assess customer requirements and collaborate with broader manufacturing and engineering teams to establish process control plans that meet specifications.
  • Monitor and adjust key operating parameters to achieve optimal yield, consistent product quality, and minimal environmental impacts.
  • Oversee daily quality control practices, driving initiatives to maintain stable and efficient powder processing operations.
  • Lead investigations and resolutions of quality-related issues within the powder production domain.
  • Perform additional duties as assigned.

Basic Qualifications:

  • Bachelor's degree in Metallurgy/Materials Science, Mechanical Engineering, Chemical Engineering, Chemistry, or a related technical discipline.
  • 3-5 years of experience in industrial-scale metal powder processing.
  • In-depth knowledge of powder metallurgy processes and quality control fundamentals.
  • Experience in gathering and analyzing process control data for Statistical Process Control (SPC).
  • Proficient in problem-solving methodologies (FMEA, 8D, A3, Root Cause Analysis).
  • Familiarity with equipment diagnostics, process development, PLCs, and P&ID.
  • Strong written and verbal communication skills.
  • Proficient in Microsoft Office applications.

Preferred Qualifications:

  • 5+ years of industrial experience in powder manufacturing and processing.
  • Extensive technical knowledge of metal powder production, particularly in milling and hydrogen decrepitation.
  • Practical experience in the safe handling of metal powders.
  • Familiarity with SAP software.
  • Ability to identify and resolve issues while effectively communicating solutions to various stakeholders.
  • Experience with programming and process control tools such as P&ID, PLC, CFD, MATLAB, Python, Mini-Tab, AutoCAD/Solidworks.

MP Materials Corp. is an Equal Opportunity/Affirmative Action Employer - All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, protected veteran status, or any other characteristic protected by law.

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