---
title: 'Senior Design Engineer at Vulcan Elements'
canonical: 'https://feeny.ai/job/senior-design-engineer-vulcan-elements-research-triangle-park-7d4bmba9bfcw'
type: 'job'
last_seen: '2026-11-01'
---

# Senior Design Engineer at Vulcan Elements

- **Company:** Vulcan Elements
- **Location:** Research Triangle Park, NC
- **Posted:** 2026-10-27
- **Last confirmed live:** 2026-11-01
- **Apply:** https://job-boards.greenhouse.io/vulcanelements/jobs/5461621008

## Job description

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 Integrity.

The CAD Designer owns new designs for parts and equipment in our R&D and pilot facility, from initial measurements and concepts through fabrication drawings, assembly and as-built documentation.This role uses SolidWorks, Fusion 360 or similar CAD software to turn evolving process needs into practical, buildable parts and assemblies.The ideal candidate combines strong mechanical design skills with hands-on machining, building, welding, repair or similar experience, and works closely with engineers, technicians and fabricators to make designs work in practice.

## Responsibilities

Mechanical Design and Development

- Design reactor parts, refractory geometry, cathodes, lids, and replacement components for high-temperature molten-salt electrochemical cells.
- Develop powder-metal feed-system parts, including hoppers, feed chutes, interfaces and mechanisms.
- Add features to machined components and design tooling, fixtures and equipment modifications for R&D and pilot projects.
- Create parametric 3D models and assemblies; check fits, interference, clearances and access for installation and maintenance.
- Work with engineers to incorporate material compatibility, thermal expansion, electrical isolation and cooling requirements into reviewed designs.

Fabrication and Build Support

- Design for available manufacturing methods and practical shop constraints, including:
- Machining access, achievable tolerances, standard stock sizes and inspection requirements.
- Weld access, assembly sequence, fasteners and serviceability.
- Measure existing equipment and reverse-engineer worn or undocumented parts; verify critical dimensions before fabrication.
- Work directly with machinists, welders, suppliers and technicians to resolve build issues, check fit and improve designs after testing.

Drawings and Spare Parts

- Produce fabrication-ready drawings with dimensions, tolerances, materials, finishes and applicable weld details.
- Maintain bills of materials, part numbers, CAD files and revision-controlled drawing packages.
- Own spare-part drawings and update as-built records so replacement parts can be ordered and installed reliably.
- Support supplier quotations and review proposed manufacturing changes with the responsible engineer.
- Manage multiple design requests and communicate priorities, lead times and design changes to the project team.

Responsibilities and tasks outlined are not exhaustive and may change as determined by the needs of the business.

## Qualifications

- Technical training in CAD, drafting or mechanical design, or equivalent practical experience.
- Demonstrated experience designing mechanical parts and assemblies in SolidWorks, Fusion 360 or similar parametric CAD software.
- Hands-on experience in machining, fabrication, welding, equipment assembly, repair or a similar trade.
- Ability to produce clear shop drawings and apply appropriate dimensions, tolerances and fits.
- Ability to use measuring tools and translate physical parts and equipment into accurate CAD models.
- Understanding of manufacturing constraints and how design choices affect cost, lead time and buildability.
- Ability to incorporate feedback from the shop floor and work through design changes in a fast-moving R&D environment.
- Strong attention to detail, organized documentation and clear communication with engineers, technicians and suppliers.

Must be a U.S. Person due to required access to U.S. export-controlled information or facilities.

## Preferred Qualifications

- Experience with high-temperature equipment, materials selection at high temperature, or metals processing equipment.
- Experience with powder handling, press feed systems, tooling or precision-machined components.
- Experience with copper busbars or buspipes, cooled assemblies, weldments or refractory components.
- Familiarity with GD&T, tolerance stack-ups, CAD data management or CAM workflows.
- Experience supporting pilot plants, prototype builds or equipment commissioning.

## About Vulcan Elements

## Company Overview
- **One-liner**: Vulcan Elements manufactures American rare-earth permanent magnets to build a resilient, Western supply chain for critical industries including defense, aerospace, automotive, and AI datacenters.
- **Entity Type**: Private (Seed + Series A + Debt financing)
- **Headquarters**: Cambridge, Massachusetts, United States (primary R&D operations also in Research Triangle Park, NC)
- **Founded**: 2023
- **Founders**: John Maslin (CEO) and Dr. Piotr Kulik (CTO)

## Core Business
- Primary industry: Advanced manufacturing of rare earth permanent magnets (neodymium).
- Target customers: B2B and government/defense – enterprise customers in defense, aerospace, automotive, industrial, consumer electronics, AI datacenters, semiconductor fabrication.
- Mission: "Improving U.S. and allied security by producing the Rare Earth Magnets that are critical to economic and national security." – [vulcanelements.com](https://vulcanelements.com/)

## Products & Services
- **Rare Earth Permanent Magnets (Neodymium)**: High-performance sintered and bonded magnets used in motors, generators, sensors, and actuators. Application areas include defense systems, satellites, AI datacenters, semiconductor fabrication, consumer electronics, industrial motors, power tools, and non-drive train motors. – [vulcanelements.com](https://vulcanelements.com/)
- **R&D and Process Optimization**: Developing next-generation magnetic technologies and advanced manufacturing processes focused on efficiency, cost competitiveness, and supply chain transparency. – [vulcanelements.com](https://vulcanelements.com/)

## Market Standing
- **Valuation**: Not publicly disclosed.
- **Total Funding**: $690.2 million (as of November 2025) across three rounds:
  - Seed Round (Dec 2023): $5.2M – 3 investors.
  - Series A (Sep 2025): $65M – led by Washington Harbour Partners and Altimeter.
  - Debt Financing (Nov 2025): $620M – led by the Department of Defense’s Office of Strategic Capital (OSC). – [cbinsights.com](https://www.cbinsights.com/company/vulcan-elements) / [linkedin.com](https://www.linkedin.com/company/vulcan-elements)
- **Key Metric**: Total funding $690.2M; production output of 10 metric tons in 2025.
- **Notable Investors/Partners**: Department of Defense’s Office of Strategic Capital, Washington Harbour Partners, Altimeter.
- **Growth Signals**: 
  - Announced a $1.4 billion partnership with the United States government.
  - Selected Benson, North Carolina, for a 1.1 million sq ft facility – the largest magnet manufacturing plant outside China.
  - Employee headcount of 38 (+200% YoY) as of mid-2026.
  - Rapidly scaling pilot operations; 37 open job listings on Greenhouse. – [vulcanelements.com](https://vulcanelements.com/) / [linkedin.com](https://www.linkedin.com/company/vulcan-elements) / [greenhouse.io](http://job-boards.greenhouse.io/vulcanelements)

## Competitive Advantages
- **Domestic Supply Chain**: The only U.S. company vertically integrating rare earth magnet production, reducing reliance on Chinese supply.
- **Technical Expertise**: Co-founder Dr. Piotr Kulik is one of four rare earth magnet science professors in the U.S. and opened the first academic rare earth magnetics lab in the country in over 20 years.
- **Government Backing**: Strong ties to U.S. national security agencies and over a billion dollars in government-funded partnerships.
- **Process Innovation**: Proprietary process optimization methods aimed at cost competitiveness without sacrificing performance.
- **National Security Focus**: All operations require U.S. Person status, aligning with defense and aerospace customer needs.

## Strategic Focus
- **Scale Production**: Transition from pilot-scale (10 metric tons/year) to mass production at the Benson, NC facility to meet surging demand from defense, AI, and automotive sectors.
- **Supply Chain Resilience**: Partnering exclusively with U.S. and allied-country suppliers (UK, Australia, Japan).
- **R&D**: Developing next-generation magnetic materials and advanced manufacturing processes.
- **Talent Acquisition**: Actively hiring engineers, scientists, operations, and business development talent to support rapid growth. – [greenhouse.io](http://job-boards.greenhouse.io/vulcanelements)

## Why Work Here
- **Mission-Driven Culture**: Employees contribute directly to national security and economic resilience, with values of Mission Focus, Technical Excellence, and Transparency. – [vulcanelements.com](https://vulcanelements.com/careers/)
- **Benefits**: Competitive equity, unlimited PTO, 90% health insurance (100% for employee), 99% dental and vision, 401K, fully stocked kitchen. – [vulcanelements.com](https://vulcanelements.com/careers/)
- **Work Environment**: Fast-paced startup with a "startup manufacturer" ethos; roles are largely on-site in Research Triangle Park, NC or Benson, NC. Internship opportunities available with mentorship and real impact on critical projects.
- **Growth Opportunity**: Extremely high headcount growth (+200% YoY) and large-scale facility expansion offer rapid career advancement.
- **U.S. Person Requirement**: Many positions require U.S. Person status due to government contracts.

## Sources
1. [vulcanelements.com](https://vulcanelements.com/)
2. [vulcanelements.com/careers](https://vulcanelements.com/careers/)
3. [greenhouse.io (Vulcan Elements jobs)](http://job-boards.greenhouse.io/vulcanelements)
4. [linkedin.com/company/vulcan-elements](https://www.linkedin.com/company/vulcan-elements)
5. [cbinsights.com/company/vulcan-elements](https://www.cbinsights.com/company/vulcan-elements)

## Other roles at Vulcan Elements

- [Security & Emergency Services Manager](https://feeny.ai/job/security-emergency-services-manager-vulcan-elements-benson-kqjnfejc4mtg) — Benson, NC
- [Maintenance Technician (R&D)](https://feeny.ai/job/maintenance-technician-r-d-vulcan-elements-research-triangle-park-vmbqxjwqqd14) — Research Triangle Park, NC
- [Safety Specialist](https://feeny.ai/job/safety-specialist-vulcan-elements-benson-289d9hnqpkyt) — Benson, NC
- [Staff Production Control Engineering Analyst](https://feeny.ai/job/staff-production-control-engineering-analyst-vulcan-elements-benson-ar3f3045a3cb) — Benson, NC
- [Business Systems Engineer](https://feeny.ai/job/business-systems-engineer-vulcan-elements-benson-206rjt2thmg0) — Benson, NC
- [Materials Characterization Engineer](https://feeny.ai/job/materials-characterization-engineer-vulcan-elements-research-triangle-park-kxxg1teeyjgm) — Research Triangle Park, NC
- [Manufacturing Instructor](https://feeny.ai/job/manufacturing-instructor-vulcan-elements-benson-7wex3veqf7b5) — Benson, NC
- [Laboratory Technician – Materials Characterization](https://feeny.ai/job/laboratory-technician-materials-characterization-vulcan-elements-research-dyjdvhdanh07) — Research Triangle Park, NC
- [Safety Manager](https://feeny.ai/job/safety-manager-vulcan-elements-research-triangle-park-pt78qasw38w5) — Research Triangle Park, NC
- [Maintenance Manager](https://feeny.ai/job/maintenance-manager-vulcan-elements-benson-16xbaat3zj0e) — Benson, NC