Process Engineer - Furnaces

USA Rare Earth, LLC•Stillwater, OK

10d

About The Position

We are seeking a Process Engineer – Furnaces to lead the design, operation, and optimization of all furnace-based thermal processes within our fast-growing magnet manufacturing start-up. This role will oversee hydrogen decrepitation (HD), vacuum sintering, post-sintering heat treatment, and grain boundary diffusion furnace operations, ensuring precise temperature control, atmosphere management, and cooling system performance. You’ll play a key role in driving process efficiency, safety, and product quality across critical thermal processing stages in a dynamic, high-growth production environment.

Requirements

Bachelor’s degree in Mechanical Engineering, Chemical Engineering, Materials Science, or a related field (advanced degree preferred).
3–5 years of experience with thermal processing operations such as vacuum sintering, heat treatment, or furnace system design and control.
Proficiency in process modeling, data analysis, and statistical process control (SPC).
Strong problem-solving and troubleshooting skills related to temperature control, atmosphere management, and process efficiency.
Knowledge of safety, quality, and industry standards for thermal and materials processing.
Experience implementing process improvements and maintaining equipment reliability in a manufacturing environment.
Ability to collaborate effectively in a cross-functional, fast-paced start-up environment.

Responsibilities

Develop, maintain, and optimize process parameters for all furnace types to ensure consistent part density, magnetic properties, and yield.
Oversee installation, startup, and qualification of furnace systems, including vacuum systems, gas delivery, water cooling, and safety interlocks.
Author and maintain standard operating procedures (SOPs), PFMEAs, and control plans for each furnace type.
Monitor process data (temperature curves, vacuum levels, gas flow, etc.) for trends and deviations; implement corrective actions.
Collaborate with Facilities and EHS teams on safety systems: hydrogen management, venting, alarms, emergency protocols, etc..
Lead troubleshooting and root cause analysis for nonconforming material or equipment issues.
Interface with vendors for design reviews, FAT/SAT, maintenance planning, and spare parts management.
Coordinate closely with other Process Engineers on material transitions and furnace recipes specific to processes that involve the use of furnaces.
Support quality and R&D teams in furnace trials, new material qualifications, and metallurgical evaluations.
Develop process capability metrics and support automation/instrumentation improvements for repeatability.