Senior Machining Process Engineer – R&D

Vulcan Elements is manufacturing American rare-earth permanent magnets for a secure, resilient future. With a focus on national security and economic resiliency, we serve critical industries such as defense, aerospace, and automotive powering a high-technology future. Vulcan Elements is building a team of ambitious professionals committed to Mission Focus, Technical Excellence and Transparency. Sintered NdFeB magnets are a challenge to machine and finish: hard, brittle, chip-prone, corrosion-sensitive. As a Machining Process Engineer you will own the key performance indicators for machining and finishing processes that turn sintered magnet blocks into finished coating-ready parts. You will evaluate and optimize machining pathways, including wire sawing, precision grinding, tumbling, and other processes. The ideal candidate is a hands-on abrasive machining expert who can also make a detailed and quantitative process flow diagram. You will improve existing machining methods, including slicing, grinding, chamfering, and surface prep. You will select and qualify new shaping processes from lab-scale development to validated, documented production handoff. Responsibilities Process Characterization, Metrology Quality • Metrology, surface finish, and inspection methods • Establish SPC and capability baselines and drive loss/defect rates down with data Equipment Specification New Process Introduction (NPI) • Evaluate, specify, and justify new machining and finishing processes to Vulcan; run vendor trials, define acceptance criteria. • Document developed processes and hand off validated, capable processes to pilot production — including processes destined for future high-volume magnet factory programs. Optimization of Existing Machining Processes • Develop and optimize slicing, grinding, abrasive, tumbling processes • Minimize loss and maximize material yield while holding thickness tolerance, TTV, bow, and warp targets; quantify the yield-vs-throughput trade space for varying magnet geometries. • Development of novel tooling and fixturing as needed • Understand and quantify surface effects on downstream coating adhesion, corrosion, and magnetic performance. Responsibilities and tasks outlined are not exhaustive and may change as determined by the needs of the business We are looking for depth in abrasive machining plus the range to own everything around it: • Abrasive Machining of Hard/Brittle Materials: Direct experience machining sintered magnets, technical ceramics, carbide, glass, silicon/semiconductor wafers, or similar brittle materials. • Diamond Tooling: Working knowledge of diamond wire, wheel, and media specification. • Machine Craft: Comfortable at the machine: setup, alignment, fixturing, troubleshooting vibration and chatter. • Coolant Filtration Systems: Practical understanding of coolant chemistry, delivery, filtration technologies, and swarf/sludge handling. • Statistics DOE: Fluency in designed experiments, measurement system analysis, SPC, and capability studies. • Metrology GD T: Strong command of GD T interpretation and precision dimensional/surface metrology at micron scale. • CAD Fixture Design: Able to design and iterate workholding, carriers, and handling fixtures (SolidWorks, Fusion 360, or similar). Qualifications • B.S. in Mechanical Engineering, Manufacturing Engineering, Materials Science, or equivalent hands-on experience. • 5+ years of process engineering experience in machining/finishing. • Demonstrated ownership of a machining process from development through production release. • Experience with NdFeB or other permanent magnet materials is a strong plus, but we will gladly teach magnets to someone who deeply knows grinding. Must be a U.S. Person due to required access to U.S. export-controlled information or facilities. Desired Skills • Experience in semiconductor wafering, optics fabrication, cutting tool manufacturing, or technical ceramics. Laboratory Safety and PPE Requirements This role requires strict adherence to all laboratory safety protocols and regulatory guidelines. Employees must consistently wear appropriate personal protective equipment (PPE), including lab coats, safety glasses, gloves, and any additional gear required for specific materials or processes. The position involves working around equipment and procedures that present cut hazards and other physical risks associated with slicing, grinding, and tumbling operations. Team members must follow all established safety rules, use tools and machinery only as trained, and maintain awareness of mechanical pinch points, sharp components, and moving parts. Employees are expected to maintain a clean and compliant work area, promptly report any unsafe conditions, and complete all required safety training. A strong commitment to maintaining a safe and compliant laboratory environment is essential for success in this role.