R&D Engineer

USA Rare Earth R&D Engineer

USA Rare Earth is 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.

Position Overview:

The R&D Engineer supports the development and scale-up of rare earth processing technologies, focusing on extraction, separation, and purification from primary and recycled feedstocks. This role is highly hands-on, bridging lab research and pilot plant operations to advance processes toward commercial readiness.

Key Responsibilities

• Design and execute experiments for rare earth leaching, solvent extraction, and purification.
• Translate bench-scale work into pilot-scale operations, supporting scale-up and process optimization.
• Operate and support pilot plant systems, including test planning, data collection, and troubleshooting.
• Perform mass balances and analyze process data to improve recoveries, efficiency, and product quality.
• Develop technical documentation (SOPs, PFDs, test reports) to support pilot operations and scale-up.
• Collaborate with engineering and operations teams to advance process design and commercialization.
• Support safety programs, including PHAs and compliance with environmental and operational standards.
• Coordinate with external partners (EPCMs, vendors, labs) as needed.

Qualifications

• Bachelor's degree in Chemical, Metallurgical, or Materials Engineering (advanced degree a plus).
• 3–7 years of experience in hydrometallurgy, chemical processing, or process R&D.
• Experience with pilot plant operations and process scale-up.
• Familiarity with rare earth separation techniques (e.g., solvent extraction, precipitation) preferred.
• Strong data analysis, problem-solving, and process troubleshooting skills.
• Working knowledge of PFDs/P&IDs and process control systems (SCADA/DCS) is a plus.

Skills & Attributes

• Hands-on, execution-focused mindset suited for a pilot-stage environment.
• Ability to manage multiple priorities and adapt in a fast-paced setting.
• Strong communication skills and attention to detail.
• Commitment to safety, quality, and continuous improvement.

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.

Specific vision abilities required by this job include close vision and distance vision. While performing the duties of this job, the employee is regularly required to walk, stand, move, sit, carry, bend, kneel, reach, push, pull, lift, use hands and fingers, handle, or feel, and talk and hear. May be required to lift and move boxes or packages not exceeding 20 pounds in weight. Some work stress inherent to the position and extended work hours may be required.

Work Environment:

The work environment will be an office environment. Noise level: Normal office noises