Project Engineer

Who we are:

We are on a mission to become a leading supplier of critical materials that enable the green energy and technology revolution. Our materials and technologies are required for the electric vehicle, green energy, consumer electronics, and defense industries, and our battery grade lithium and tech metals are needed for chipsets, semiconductors, and 5G.


We have a substantial interest in the Round Top, Heavy Rare Earth, Lithium and Critical Minerals deposit in West Texas. We have also developed the United States' first rare earth and critical minerals processing facility and we own the only scalable, sintered neo-magnet manufacturing system in the Western Hemisphere. By developing this fully integrated, US-based "mine-to-magnet" critical mineral supply chain, we are poised to become the leading domestic supplier to these industries.

What you can expect:

At USA Rare Earth, we are pioneers and problem solvers, technologists and team players. Together, we:

Build Solutions : If our task was a simple one, it would already be done. We are creative and solution-oriented, and we think outside the box to solve important problems. We know that a range of expertise and technologies is needed for success, and we work across sectors and alongside customers to deliver world-class solutions in sustainable ways.

Deliver Quality : When we do things, we do them well. We believe that top-tier quality leads to industry competitiveness and we hold ourselves to the highest quality standards. We move fast when executing, but safety, quality, and excellence always come first.

Lead responsibly : We have a responsibility to the planet, our consumers, our country, and each other. We put safety at the center of all we do, take accountability for our actions, incorporate sustainable practices in our processes and act with the financial best interest of our investors and consumers in mind.

Win Together : Establishing a rare earth magnet supply chain is a big undertaking - and getting there is a team effort. We communicate openly, work together and challenge each other in pursuit of our goals. With every step we take we learn and get better.

Job Summary:
The Project Engineer leads capital projects, process improvements, and equipment upgrades within a high-temperature metal-making and alloy environment. This role bridges operations, maintenance, and technical engineering teams to ensure projects are delivered safely, efficiently, and with long-term reliability in mind. The ideal candidate is hands-on, analytical, and comfortable working in a heavy industrial setting.

As part of this role, you will be required to travel to our UK site for an initial training period. During this time, you will learn Less Common Metals' processes, standards, and operating methods. You will then serve as the trainer and project team lead within Engineering for the US site once operations commence, ensuring knowledge transfer and consistent global standards.

Key Responsibilities

Project Management

• Develop and manage project scopes, budgets, schedules, and risk registers for projects.
• Coordinate internal stakeholders, contractors, and OEMs to ensure alignment and timely execution.
• Lead project meetings, track milestones, and provide progress reports to leadership.
• Oversee installation, commissioning, and handover of new equipment and systems.

Engineering & Technical Responsibilities

• Provide engineering support for melting, casting, rolling, forging, or heat-treating operations.
• Analyse process data to identify bottlenecks, inefficiencies, and improvement opportunities.
• Support equipment specification, design reviews, and acceptance testing for furnaces, cranes, conveyors, and automation systems.
• Conduct root-cause analysis (RCA) and implement corrective actions for equipment failures or process deviations.
• Ensure engineering documentation (P&IDs, layouts, manuals, drawings) is accurate and up to date .

Safety & Compliance

• Ensure all project activities comply with site safety rules, UK regulations, and environmental standards.
• Lead hazard assessments (HAZOP, HIRA, PUWER) and implement engineering controls.
• Support continuous improvement of safety systems in high-temperature and high-energy environments.
• Promote a strong safety culture through proactive engagement and visible leadership.

Technical Team Collaboration

• Work closely with metallurgists, process engineers, and automation engineers to ensure project designs align with process requirements and product quality standards.
• Translate technical requirements into practical project deliverables, ensuring equipment and systems meet metallurgical and operational specifications.
• Facilitate technical design reviews, ensuring cross-functional input is captured early to avoid rework.
• Partner with reliability engineers to incorporate predictive maintenance strategies, condition monitoring, and lifecycle considerations into project designs.
• Collaborate with maintenance engineering to ensure new equipment is maintainable, accessible, and supported with proper documentation and spare-parts strategies.
• Support technical teams during trials, commissioning, and performance testing, ensuring data is captured and analysed effectively.
• Act as a technical liaison between the facility and external engineering firms, ensuring designs meet site standards and operational realities.

Technical Leadership

• Provide engineering judgement during troubleshooting, shutdown planning, and equipment upgrades.
• Ensure technical teams have the resources, drawings, and information needed to execute their work.
• Lead cross-functional problem-solving sessions using tools such as 5-Why, FMEA, and fishbone analysis.
• Mentor junior engineers and technicians on project execution, technical standards, and engineering best practices.

Cross-Functional Collaboration

• Work with operations to ensure project outcomes support production goals and operator usability.
• Coordinate with procurement on vendor selection, contract negotiation, and equipment sourcing.
• Support quality teams by ensuring new equipment meets product specifications and testing requirements.
• Communicate project impacts, timelines, and risks to all stakeholders.

Qualifications

Required

• Bachelor's degree in mechanical, Electrical, Metallurgical, or Industrial Engineering (or equivalent).
• 3+ years of engineering experience in heavy industry (steel, aluminum, foundry, forging, or similar).
• Proven experience managing capital or process-improvement projects.
• Strong understanding of industrial equipment, automation, and reliability principles.
• Excellent communication, planning, and problem-solving skills.

Preferred

• Experience with molten metal handling, refractory systems, or furnace operations.
• Knowledge of lean manufacturing, Six Sigma, or TPM methodologies.
• Familiarity with CAD tools (AutoCAD, SolidWorks) and project management software.
• Chartered Engineer (CEng) status or working toward it.

Physical Demands

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

The work environment will be a mix of a typical office environment, a manufacturing floor and a construction site. Noise level: Normal office, manufacturing and construction noises.

The above statements are intended to describe the general nature and level of work being performed by people assigned to this job. They are not intended to be an exhaustive list of all responsibilities, duties, skills required of personnel so classified. The reporting relationship may not reflect the most recent changes to the corporate reporting structure.

USA Rare Earth proudly supports Equal Employment Opportunities

USA Rare Earth's policy is to provide equal employment opportunities to all applicants and will provide reasonable accommodations according to applicable federal, state, and/or local laws.

For assistance applying for employment through this site due to disability, please contact Human Resources, View email address on click.appcast.io, to discuss reasonable accommodations.