Position Overview: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-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.
Position 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, squareness, concentricity, and perpendicularity.
- Review customer drawings and specifications, design and optimize DFM (Design for Manufacturability) of new magnet components, develop prototypes, modify existing parts, and improve machining processes.
- Conduct statistical analysis of machining data, including Cpk/Ppk, gauge R&R, and SPC charts, to monitor and improve process capability.
- Oversee installation, operation, troubleshooting, maintenance, and repair activities to ensure that pilot manufacturing equipment are installed and operate in accordance with specifications.
- 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.
- Mentor and manage engineers and technicians to ensure high-quality execution of experimental trials and data collection, and provide technical guidance 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.
Basic Qualifications:- 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, tolerance stack-up analysis, and DFM (Design for Manufacturability).
- 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-functional team.
- Excellent written and verbal communication skills.
Desired Qualifications: - 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.
