Senior Engineer, Magnet Technology

MP Materials Corp.•Fort Worth, TX

52d

About The Position

MP Materials is seeking a hands-on Senior Engineer to lead the development and optimization of precision machining processes and dimensional control strategies for high-performance, rare earth permanent magnets. This role is critical to enabling manufacturability of complex magnet geometries with micron[1]level tolerances. The ideal candidate will bring deep expertise in geometric dimensioning and tolerancing (GD&T), statistical process control (SPC), and process capability analysis (E.g. Cpk, Ppk), along with hands-on experience machining brittle materials.

Requirements

Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, or a related field.
5+ years of hands-on experience in precision machining and dimensional control, preferably involving brittle materials.
Advanced proficiency in GD&T (ASME Y14.5 standard), blueprint reading, and tolerance stack-up analysis.
Proven experience with statistical analysis tools (e.g. R, Minitab) and process capability metrics (Cpk, Ppk).
Experience designing and optimizing fixtures and tooling for complex geometries.
Fluent with CAD/CAM tools (e.g., SolidWorks).
Strong understanding of machining challenges posed by brittle, hard, or magnetized materials.
Strong analytical and problem-solving skills; ability to work independently and as part of a cross[1]functional team.
Excellent written and verbal communication skills.

Nice To Haves

Experience machining ceramics, intermetallics, composites, or rare earth magnets to micron-level tolerances.
Knowledge of advanced inspection techniques and digital metrology.
Familiarity with materials science and metallurgy concepts related to manufacturing of rare-earth magnets (e.g. sintering, magnetization, etc.).
Experience leading technical development projects, with the ability to prioritize and manage multiple concurrent projects.
Experience with programming, and the ability to apply those skills to automate routine analysis, data management, and process control operations.
Lifelong learner able and enthusiastic to apply existing skills and experiences to new problems.

Responsibilities

Lead the development and refinement of machining processes for cutting, grinding, shaping, and finishing of rare earth permanent magnets with tight dimensional tolerances and surface integrity.
Apply advanced GD&T principles (ASME Y14.5) to interpret engineering drawings and ensure precise part geometry, flatness, concentricity, and perpendicularity.
Collaborate with design and quality engineering to ensure DFM (Design for Manufacturability) of new magnet components.
Conduct statistical analysis of machining data, including Cpk/Ppk, gauge R&R, and SPC charts, to monitor and improve process capability.
Design and fabricate custom fixtures, jigs, and tooling to safely and accurately machine brittle, magnetized or demagnetized materials.
Lead root cause analysis of dimensional defects and machining errors; develop corrective actions and continuous improvement plans.
Implement process improvements to increase throughput, reduce scrap, and enhance dimensional control.
Perform hands-on prototyping and process trials, working directly with in-house equipment and technicians.
Conduct first-article inspections and support dimensional validation using vision systems, micrometers, and other metrology equipment.
Mentor junior engineers and technicians in GD&T interpretation, statistical analysis, and machining best practices.
Work closely with EHS to ensure that all work is done to ensure world-class health and safety, and full compliance with relevant environmental regulations.
Other duties as assigned.