USA Rare Earth, Inc. (Nasdaq: USAR) · 1 day ago
Process Engineer - Micro/Macro Machining
Stillwater, OK
Full-time
Onsite
Mid, Senior Level
2+ years expUSA Rare Earth, Inc. is on a mission to become the leading Western supplier of high-value rare earth magnets and critical minerals. The Process Engineer for Micro and Macro Machining is responsible for developing, optimizing, and sustaining machining processes to ensure precision and quality in the production of magnet components.
Angel InvestmentManufacturingMiningProduct Design
Responsibilities
Micro-Machining Process Development & Optimization - Develop and refine milling, grinding, EDM, laser, or diamond-cutting processes for small or fragile magnet components. Establish machining parameters (speed, feed, depth of cut, coolant flow, tool paths). Optimize for accuracy, surface finish, and minimal chipping/cracking
Tooling & Fixturing Design - Specify micro-cutting tools, abrasives, wheels, or nozzles. Design fixtures, soft jaws, or vacuum holding methods for small or brittle parts. Ensure repeatability and precision for high-volume operations
Process Monitoring & Control - Maintain SPC for critical dimensions, flatness, rough surface, and tolerances. Track tool wear and establish tool-change intervals. Monitor vibration, coolant conditions, and machine stability
Troubleshooting & Root-Cause Analysis - Address issues such as chipping, cracking, breakage, taper errors, burn marks, or uneven surfaces. Use structured problem-solving (5 Why’s, DOE, Fishbone) to drive corrective actions
Equipment Support & Upgrades - Work with maintenance on micro-machining centers, precision grinders, EDM/laser systems, and measurement tools. Support calibration, alignment, and preventative-maintenance routines. Evaluate and validate new equipment or cutting technologies
Material Characterization & Handling - Understand magnetic material behavior, brittleness, coating sensitivity, and microstructural effects during machining. Define proper handling, washing, and drying procedures to protect part surfaces
Quality Assurance - Work with Quality on inspection methods using microscopes, CMMs, laser-gauging, and optical metrology. Define sampling plans and acceptance criteria for fine tolerances
Documentation & Standards - Create/update SOPs, process flow diagrams, PFMEAs, and control plans. Maintain machining recipes, tool libraries, and change histories
New Product Introduction (NPI) - Support prototype machining, characterization, and capability studies. Establish production-ready machining parameters for new part geometries or materials
Safety & Continuous Improvement. Enforce safety practices around fine particulate, coolants, lasers, and precision machinery. Lead projects to increase throughput, reduce scrap, improve tool life, or tighten tolerances
Machining Process Development & Optimization - Develop and refine milling, turning, grinding, or sawing processes for larger magnet parts. Establish machining parameters (speed, feed, depth of cut, coolant flow, tool paths) for robust, repeatable performance. Optimize for dimensional accuracy, surface finish, and minimal chipping or cracking in brittle materials
Tooling & Fixturing Development - Specify cutting tools, wheels, inserts, and fixtures suitable for magnet or special-material machining. Design or improve holding systems (clamps, jigs, soft jaws, magnetic/vacuum fixtures). Improve changeover efficiency and reduce setup variability
Process Monitoring & Control - Maintain SPC on critical dimensions, flatness, concentricity, and tolerances. Track tool life, vibration, coolant condition, and machine performance. Ensure consistent machining performance across shifts and machines
Troubleshooting & Root-Cause Analysis - Resolve issues such as poor surface finish, out-of-tolerance dimensions, chipping, breakage, or excessive tool wear. Use structured problem-solving methods (DOE, 5 Why’s, Fishbone) to implement corrective actions
Equipment & Maintenance Support - Work with maintenance on machining centers, grinders, saws, and material-handling equipment. Support calibrations, alignment checks, PM routines, and machine restorations. Evaluate upgrades or new machining equipment for capability and capacity
Material Handling & Protection - Define proper handling, staging, and transportation of larger magnet components to prevent damage. Ensure alignment with downstream processes such as grinding, coating, or assembly
Quality Assurance Collaboration - Define measurement methods using calipers, micrometers, bore gauges, CMMs, or optical systems. Establish sampling plans and acceptance criteria for key dimensions and surface characteristics. Support failure analysis for machining-related defects
Documentation & Standards - Create/update SOPs, machining recipes, control plans, PFMEAs, and process flow diagrams. Maintain tooling libraries, fixture drawings, and process change records
New Product Introduction (NPI) - Support prototype machining, capability studies, and development of machining standards for new magnet designs. Transition successful trials to full-scale production
Safety & Continuous Improvement - Ensure safe operation of machining equipment, including coolant handling, chip control, and lifting operations. Lead improvement projects focused on cycle-time reduction, scrap reduction, and tool-life extension
Qualification
Required
Bachelor's degree in mechanical engineering, Manufacturing Engineering, Materials Science, or similar
2–5+ years' experience in machining, micro-machining, precision grinding, or EDM/laser processing
Strong understanding of GD&T, precision tolerances, and tool/material interactions
Experience with root-cause analysis and SPC
Experience machining brittle materials (ceramics, magnets, glass, ferrites, hard alloys)
Familiarity with precision metrology (CMM, optical, laser)
Knowledge of lean manufacturing and ISO9001/IATF16949
Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, or related field
2–5+ years of machining or manufacturing engineering experience
Strong understanding of machining fundamentals, GD&T, and tooling interactions
Experience with SPC and structured problem-solving
Company
USA Rare Earth, Inc. (Nasdaq: USAR)
USA Rare Earth, LLC is a U.S.-based, vertically integrated magnet technology company.
11-50 employees
H1B Sponsorship
USA Rare Earth, Inc. (Nasdaq: USAR) has a track record of offering H1B sponsorships. Please note that this does not
guarantee sponsorship for this specific role. Below presents additional info for your
reference. (Data Powered by US Department of Labor)
Distribution of Different Job Fields Receiving Sponsorship
Represents job field similar to this job
Trends of Total Sponsorships
2025 (2)
Funding
Current Stage
Public CompanyTotal Funding
$202.56MKey Investors
Navajo Transitional Energy Company
2025-04-30Post Ipo Equity· $75M
2025-03-13Post Ipo Equity· $50M
2025-03-13IPO
Leadership Team
Alex Moyes
Vice President of Mining
Recent News
The Motley Fool
2026-01-06
2026-01-05
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2025-12-29
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