Senior Engineer, Metal Making

MP Materials Corp.•Fort Worth, TX

About The Position

MP Materials is seeking a hands-on Senior Engineer to lead the development of advanced technologies for producing high-purity rare earth metal and alloys, critical for high-performance permanent magnets. This role focuses on developing and scaling electrometallurgical and pyrometallurgical technologies – including but not limited to molten salt electrolysis and metallothermic reduction The ideal candidate will bring deep expertise in extractive metallurgy, and apply a combination of experimental research, process modeling, and material science expertise to design, optimize, and scale metal making pathways. This position will play a pivotal role in restoring strategic manufacturing capabilities to the U.S.

Requirements

Ph.D. in Materials Science & Engineering, Metallurgy, Chemical Engineering, Electrochemistry, or related field.
3+ years of hands-on experience with molten salt electrolysis and/or metallothermic reduction processes.
Experience with electrochemical instrumentation and techniques.
Strong theoretical and experimental background in electrochemistry, transport phenomena, thermodynamics, and kinetics.
Agile researcher, adept at identifying untested questions about materials and processes.
Excellent written and verbal communication skills.

Nice To Haves

Experience building furnace reactors, electrolysis cells, and custom experimental setups for electrometallurgy and/or pyrometallurgy processes.
Experience with rare earth metal, alloy, and/or magnet making processes.
Experience leading technical development projects, with the ability to prioritize and manage multiple concurrent projects.
Experience with thermodynamic modeling software such as FactSage and simulation tools such as finite element analysis and computational fluid dynamics.
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 optimization of rare earth metal and alloy production processes.
Design and execute laboratory and pilot-scale experiments involving high-temperature reaction kinetics, molten salt systems, and reduction pathways.
Apply simulation tools to model the thermodynamics, transport phenomena, and electrochemical behavior in rare earth metal extraction and refining.
Translate lab and pilot-scale findings into scalable, production ready processes.
Collaborate cross-functionally with R&D, manufacturing, and quality teams to align process development with operational goals.
Characterize materials using techniques such as XRD, XRF, LECO, and SEM.
Utilize electrochemical instrumentation (e.g., galvanostats, potentiostats) and techniques (e.g., cyclic voltammetry, impedance spectroscopy) to tune and evaluate processes.
Document all projects, provide written guidance for model usage, and build team knowledge of current and future rare earth research.
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 .
Engage with university researchers, strategic partners, and government laboratories involved in rare earth reduction research to bring value and knowledge to MP Materials.
Other duties as assigned