Senior Process Engineer, Strip Casting

MP Materials Corp. • Fort Worth, TX

76d

About The Position

MP Materials is seeking a hands-on process engineer specializing in the strip casting metal alloys. The role requires a combination of technical expertise, problem-solving skills, and collaborative abilities to drive the development and optimization of cleaning and coating process. The ideal candidate will have hands-on experience vacuum induction melters, and alloying technologies. The process engineer must be comfortable with failure analysis, continuous improvements, equipment fault diagnosis, and process development.

Requirements

• Bachelor's degree in metallurgical or chemical engineering, chemistry, materials science and relevant field experience.
• 3-5 years of experience in process engineering roles focused on alloying and casting.
• Experience of implementing statistical process control (SPC) for industrial manufacturing.
• Strong knowledge of melting metals in inert environments, strip casting or melt spinning, microstructure evaluation.
• Proficient with statistical analysis tools and methodologies for process optimization (e.g., Six Sigma, Design of Experiments, Root).
• Excellent problem-solving skills and the ability to analyze complex technical issues and develop practical solutions.
• Effective communication skills and the ability to collaborate cross-functionally with engineering, manufacturing, and quality teams.
• Strong commitment to safety, quality, and continuous improvement initiatives.

Nice To Haves

• 5+ years of experience of industrial experience powder manufacturing, processing, and/or conducting powder metallurgy processes.
• Practical experience of the process safety associated with metal powder processing.
• Experience with SAP.
• Ability to identify and solve problems and convince others (management down to operators) that your solution is the right one.

Responsibilities

• Develop, optimize, and maintain the strip casting process for Neodymium magnets (also known as rare earth magnets).
• Implement process monitoring and control systems to maintain optimal casting conditions, control flake thickness and microstructure.
• Collaborate with different teams and external vendors to operate, optimize and maintain the production strip casting units.
• Troubleshoot equipment and process issues, root cause analysis, and implement corrective actions to resolve production disruptions and improve process robustness.
• Provide technical support and training to production personnel on coating techniques, equipment operation, and safety procedures.
• Lead process improvements, failure analysis, defect reduction, root cause analysis, and fault diagnostics.
• Define casting parameters, machine settings, and quality standards to ensure consistent production performance and adherence to customer requirements.
• Other duties, as assigned.

What This Job Offers

• Education Level: Bachelor's degree
• Number of Employees: 501-1,000 employees