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 low-carbon technologies that drive contemporary life, from electric vehicles to renewable energy systems. We seek passionate, mission-oriented individuals eager to tackle challenges and make a difference. Our core values emphasize collaboration, resilience, and integrity, with a steadfast commitment to our workforce, community, and the environment.

The Process Engineer – Powder will play a pivotal role in the design and establishment of a cutting-edge facility for metal, alloy, and magnet production. This position offers a unique chance to contribute significantly to the development of a new advanced manufacturing site, shaping the future of manufacturing in America. The ideal candidate will possess practical experience in managing metal powder production processes, including powder transport, 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 range of technical experts to gain insights into the physical processes, critical control metrics, and potential risks associated with the entire manufacturing workflow.

Key Responsibilities:

  • Deliver technical coordination and support for powder processing operations to fulfill all internal and customer specifications.
  • Collaborate with production teams across upstream and downstream processes to ensure efficient integration throughout all manufacturing operations.
  • Provide technical training and assistance to production personnel.
  • Engage with procurement, vendors, maintenance teams, operators, and other stakeholders on equipment specifications, design evaluations, and the commissioning of new facilities.
  • Contribute to EHS risk assessments, HAZOP studies, regulatory compliance initiatives, and related activities.
  • Plan, execute, and assist in the development of processes and procedures for hydrogen decrepitation (HD) furnaces, jet milling, and other powder processing techniques.
  • Work closely with the R&D team to advance new process developments, facilitating the rapid deployment of innovative 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 high yield, consistent product quality, and minimal EHS impacts.
  • Oversee the daily implementation of quality control procedures, driving initiatives to ensure stable and efficient powder processing operations.
  • Identify and lead investigations into quality issues within the powder production sector.
  • Perform additional duties as assigned.

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 for part manufacturing 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, etc.).
  • Familiarity with equipment diagnostics, process development, PLCs, and P&ID.
  • Strong written and verbal communication skills.
  • Proficient in Microsoft Office applications.

Preferred Attributes:

  • 5+ years of experience in industrial powder manufacturing and processing.
  • Extensive technical knowledge of metal powder production, particularly milling and hydrogen decrepitation.
  • Practical experience in the safe handling of metal powders.
  • Familiarity with SAP systems.
  • Ability to identify and resolve issues while effectively communicating solutions to diverse stakeholders.
  • Experience with programming and process control tools; 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. Underrepresented groups/Women/Disabled/Veterans are encouraged to apply.

Your Right to Work – In compliance with federal law, all persons hired will be required to verify identity and eligibility to work in the United States.

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