Process Engineer - Pressing (and green cut)

USA Rare Earth, LLC•Stillwater, OK

About The Position

We are seeking a Process Engineer – Pressing to lead the design, operation, and optimization of all pressing processes within our fast-growing magnet manufacturing start-up. This role will oversee operations from jet-milled powder through pressing, green part handling, and cutting, ensuring process stability, magnetic alignment, and uniform green density. You’ll play a key role in managing recycles and slurry systems while driving consistent product quality and efficient downstream operations in a dynamic, high-growth production environment.

Requirements

Bachelor’s degree in Mechanical Engineering, Chemical Engineering, Materials Science, or a related field (advanced degree preferred).
3–5 years of experience in pressing, powder handling, or materials processing.
Proficiency in slurry preparation, wet pressing parameters, green part handling, and tooling/magnetic field setup.
Strong analytical and problem-solving skills, including data analysis and statistical process control (SPC).
Knowledge of SOPs, FMEAs, and quality control for pressing operations.
Ability to collaborate effectively with cross-functional teams in a fast-paced, start-up environment.
Experience managing recycles, slurry re-use, and optimizing process stability and yield.

Responsibilities

Define and maintain slurry preparation and wet pressing parameters to achieve consistent green density and orientation.
Oversee press setup, tooling design, and magnetic field application during pressing.
Develop processes for green cutting, trimming, and part separation.
Establish handling methods to minimize green part damage prior to sintering.
Manage green recycles and slurry re-use processes, ensuring quality control.
Develop and maintain SOPs, FMEAs, and control documentation.
Analyze press data (force, alignment, density) and drive improvements in yield and process stability.
Interface with Maintenance and Facilities on press utilities, cooling, and magnetic field systems.
Collaborate with Furnace Engineer for green part drying, pre-sintering loading, and tray design.
Participate in equipment selection and qualification for presses, dryers, and cutting systems. This includes both wet pressing systems and future dry pressing systems that require more protected environmental considerations.