Senior Machining Process Engineer – R&D

<p>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.</p>
<p><span data-contrast="auto"> Sintered NdFeB magnets are a challenge to machine and finish: hard, brittle, chip-prone, corrosion-sensitive. </span><span data-contrast="auto">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.</span><span data-ccp-props="{"335559739":120}"> </span></p>
<p><span data-contrast="auto">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.</span><span data-ccp-props="{"335559739":120}"> </span></p>
<p><strong><span data-contrast="auto"> Responsibilities</span></strong><span data-ccp-props="{"335559738":200,"335559739":100,"335572079":6,"335572080":4,"335572081":4473924,"469789806":"single"}"> </span></p>
<p><strong><span data-contrast="auto">Process Characterization, Metrology & Quality</span></strong><span data-ccp-props="{"335559738":160,"335559739":60}"> </span></p>
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<li data-leveltext="•" data-font="" data-listid="2" data-list-defn-props="{"335552541":1,"335559685":720,"335559991":360,"469769242":[8226],"469777803":"left","469777804":"•","469777815":"hybridMultilevel"}" data-aria-posinset="1" data-aria-level="1"><span data-contrast="auto">Metrology, surface finish, and inspection methods</span><span data-ccp-props="{"335559738":160,"335559739":60}"> </span></li>
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<li data-leveltext="•" data-font="" data-listid="2" data-list-defn-props="{"335552541":1,"335559685":720,"335559991":360,"469769242":[8226],"469777803":"left","469777804":"•","469777815":"hybridMultilevel"}" data-aria-posinset="2" data-aria-level="1"><span data-contrast="auto">Establish SPC and capability baselines and drive loss/defect rates down with data</span></li>
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<p><strong><span data-contrast="auto">Equipment Specification & New Process Introduction (NPI)</span></strong><span data-ccp-props="{"335559738":160,"335559739":60}"> </span></p>
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<li data-leveltext="•" data-font="" data-listid="2" data-list-defn-props="{"335552541":1,"335559685":720,"335559991":360,"469769242":[8226],"469777803":"left","469777804":"•","469777815":"hybridMultilevel"}" data-aria-posinset="3" data-aria-level="1"><span data-contrast="auto">Evaluate, specify, and justify new machining and finishing processes to Vulcan; run vendor trials, define acceptance criteria.</span><span data-ccp-props="{"335559738":160,"335559739":60}"> </span></li>
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<li data-leveltext="•" data-font="" data-listid="2" data-list-defn-props="{"335552541":1,"335559685":720,"335559991":360,"469769242":[8226],"469777803":"left","469777804":"•","469777815":"hybridMultilevel"}" data-aria-posinset="4" data-aria-level="1"><span data-contrast="auto">Document developed processes and hand off validated, capable processes to pilot production — including processes destined for future high-volume magnet factory programs.</span><span data-ccp-props="{"335559738":160,"335559739":60}"> </span></li>
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<p><strong><span data-contrast="auto">Optimization of Existing Machining Processes</span></strong><span data-ccp-props="{"335559738":160,"335559739":60}"> </span></p>
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<li data-leveltext="•" data-font="" data-listid="2" data-list-defn-props="{"335552541":1,"335559685":720,"335559991":360,"469769242":[8226],"469777803":"left","469777804":"•","469777815":"hybridMultilevel"}" data-aria-posinset="5" data-aria-level="1"><span data-contrast="auto">Develop and optimize slicing, grinding, abrasive, tumbling processes</span><span data-ccp-props="{"335559739":60}"> </span></li>
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<li data-leveltext="•" data-font="" data-listid="2" data-list-defn-props="{"335552541":1,"335559685":720,"335559991":360,"469769242":[8226],"469777803":"left","469777804":"•","469777815":"hybridMultilevel"}" data-aria-posinset="6" data-aria-level="1"><span data-contrast="auto">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.</span><span data-ccp-props="{"335559739":60}"> </span></li>
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<li data-leveltext="•" data-font="" data-listid="2" data-list-defn-props="{"335552541":1,"335559685":720,"335559991":360,"469769242":[8226],"469777803":"left","469777804":"•","469777815":"hybridMultilevel"}" data-aria-posinset="7" data-aria-level="1"><span data-contrast="auto">Development of novel tooling and fixturing as needed </span><span data-ccp-props="{"335559739":60}"> </span></li>
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<li data-leveltext="•" data-font="" data-listid="2" data-list-defn-props="{"335552541":1,"335559685":720,"335559991":360,"469769242":[8226],"469777803":"left","469777804":"•","469777815":"hybridMultilevel"}" data-aria-posinset="8" data-aria-level="1"><span data-contrast="auto">Understand and quantify surface effects on downstream coating adhesion, corrosion, and magnetic performance.</span><span data-ccp-props="{"335559739":60}"> </span></li>
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<p><em>Responsibilities and tasks outlined are not exhaustive and may change as determined by the needs of the business</em></p>
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<p><span data-contrast="auto">We are looking for depth in abrasive machining plus the range to own everything around it:</span><span data-ccp-props="{"335559739":120}"> </span></p>
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<li data-leveltext="•" data-font="" data-listid="2" data-list-defn-props="{"335552541":1,"335559685":720,"335559991":360,"469769242":[8226],"469777803":"left","469777804":"•","469777815":"hybridMultilevel"}" data-aria-posinset="9" data-aria-level="1"><strong><span data-contrast="auto">Abrasive Machining of Hard/Brittle Materials:</span></strong><span data-contrast="auto"> Direct experience machining sintered magnets, technical ceramics, carbide, glass, silicon/semiconductor wafers, or similar brittle materials.</span><span data-ccp-props="{"335559739":60}"> </span></li>
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<li data-leveltext="•" data-font="" data-listid="2" data-list-defn-props="{"335552541":1,"335559685":720,"335559991":360,"469769242":[8226],"469777803":"left","469777804":"•","469777815":"hybridMultilevel"}" data-aria-posinset="10" data-aria-level="1"><strong><span data-contrast="auto">Diamond Tooling:</span></strong><span data-contrast="auto"> Working knowledge of diamond wire, wheel, and media specification.</span><span data-ccp-props="{"335559739":60}"> </span></li>
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<li data-leveltext="•" data-font="" data-listid="2" data-list-defn-props="{"335552541":1,"335559685":720,"335559991":360,"469769242":[8226],"469777803":"left","469777804":"•","469777815":"hybridMultilevel"}" data-aria-posinset="11" data-aria-level="1"><strong><span data-contrast="auto">Machine Craft:</span></strong><span data-contrast="auto"> Comfortable at the machine: setup, alignment, fixturing, troubleshooting vibration and chatter.</span><span data-ccp-props="{"335559739":60}"> </span></li>
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<li data-leveltext="•" data-font="" data-listid="2" data-list-defn-props="{"335552541":1,"335559685":720,"335559991":360,"469769242":[8226],"469777803":"left","469777804":"•","469777815":"hybridMultilevel"}" data-aria-posinset="12" data-aria-level="1"><strong><span data-contrast="auto">Coolant & Filtration Systems:</span></strong><span data-contrast="auto"> Practical understanding of coolant chemistry, delivery, filtration technologies, and swarf/sludge handling.</span><span data-ccp-props="{"335559739":60}"> </span></li>
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<li data-leveltext="•" data-font="" data-listid="2" data-list-defn-props="{"335552541":1,"335559685":720,"335559991":360,"469769242":[8226],"469777803":"left","469777804":"•","469777815":"hybridMultilevel"}" data-aria-posinset="13" data-aria-level="1"><strong><span data-contrast="auto">Statistics & DOE:</span></strong><span data-contrast="auto"> Fluency in designed experiments, measurement system analysis, SPC, and capability studies.</span><span data-ccp-props="{"335559739":60}"> </span></li>
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<li data-leveltext="•" data-font="" data-listid="2" data-list-defn-props="{"335552541":1,"335559685":720,"335559991":360,"469769242":[8226],"469777803":"left","469777804":"•","469777815":"hybridMultilevel"}" data-aria-posinset="14" data-aria-level="1"><strong><span data-contrast="auto">Metrology & GD&T:</span></strong><span data-contrast="auto"> Strong command of GD&T interpretation and precision dimensional/surface metrology at micron scale.</span><span data-ccp-props="{"335559739":60}"> </span></li>
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<li data-leveltext="•" data-font="" data-listid="2" data-list-defn-props="{"335552541":1,"335559685":720,"335559991":360,"469769242":[8226],"469777803":"left","469777804":"•","469777815":"hybridMultilevel"}" data-aria-posinset="15" data-aria-level="1"><strong><span data-contrast="auto">CAD & Fixture Design:</span></strong><span data-contrast="auto"> Able to design and iterate workholding, carriers, and handling fixtures (SolidWorks, Fusion 360, or similar).</span><span data-ccp-props="{"335559739":60}"> </span></li>
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<p><strong><span data-contrast="auto">Qualifications</span></strong><span data-ccp-props="{"335559738":200,"335559739":100,"335572079":6,"335572080":4,"335572081":4473924,"469789806":"single"}"> </span></p>
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<li data-leveltext="•" data-font="" data-listid="2" data-list-defn-props="{"335552541":1,"335559685":720,"335559991":360,"469769242":[8226],"469777803":"left","469777804":"•","469777815":"hybridMultilevel"}" data-aria-posinset="16" data-aria-level="1"><span data-contrast="auto">B.S. in Mechanical Engineering, Manufacturing Engineering, Materials Science, or equivalent hands-on experience.</span><span data-ccp-props="{"335559739":60}"> </span></li>
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<li data-leveltext="•" data-font="" data-listid="2" data-list-defn-props="{"335552541":1,"335559685":720,"335559991":360,"469769242":[8226],"469777803":"left","469777804":"•","469777815":"hybridMultilevel"}" data-aria-posinset="17" data-aria-level="1"><span data-contrast="auto">5+ years of process engineering experience in machining/finishing.</span><span data-ccp-props="{"335559739":60}"> </span></li>
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<li data-leveltext="•" data-font="" data-listid="2" data-list-defn-props="{"335552541":1,"335559685":720,"335559991":360,"469769242":[8226],"469777803":"left","469777804":"•","469777815":"hybridMultilevel"}" data-aria-posinset="18" data-aria-level="1"><span data-contrast="auto">Demonstrated ownership of a machining process from development through production release.</span><span data-ccp-props="{"335559739":60}"> </span></li>
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<li data-leveltext="•" data-font="" data-listid="2" data-list-defn-props="{"335552541":1,"335559685":720,"335559991":360,"469769242":[8226],"469777803":"left","469777804":"•","469777815":"hybridMultilevel"}" data-aria-posinset="19" data-aria-level="1"><span data-contrast="auto">Experience with NdFeB or other permanent magnet materials is a strong plus, but we will gladly teach magnets to someone who deeply knows grinding.</span><span data-ccp-props="{"335559739":60}"> </span></li>
<li data-leveltext="•" data-font="" data-listid="2" data-list-defn-props="{"335552541":1,"335559685":720,"335559991":360,"469769242":[8226],"469777803":"left","469777804":"•","469777815":"hybridMultilevel"}" data-aria-posinset="19" data-aria-level="1">
<p><em><span data-contrast="auto">Must be a U.S. Person due to required access to U.S. export-controlled information or facilities.</span></em> <span data-ccp-props="{"134233117":true,"134233118":true,"201341983":0,"335557856":16777215,"335559740":240}"> </span></p>
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<p><strong><span data-contrast="auto">Desired Skills</span></strong><span data-ccp-props="{"335559738":200,"335559739":100,"335572079":6,"335572080":4,"335572081":4473924,"469789806":"single"}"> </span></p>
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<li data-leveltext="•" data-font="" data-listid="2" data-list-defn-props="{"335552541":1,"335559685":720,"335559991":360,"469769242":[8226],"469777803":"left","469777804":"•","469777815":"hybridMultilevel"}" data-aria-posinset="20" data-aria-level="1"><span data-contrast="auto">Experience in semiconductor wafering, optics fabrication, cutting tool manufacturing, or technical ceramics.</span><span data-ccp-props="{"335559739":60}"> </span></li>
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<p><span data-ccp-props="{"335559739":60}"> </span></p>