---
title: 'Senior Machining Process Engineer – R&D at Vulcan Elements'
canonical: 'https://feeny.ai/job/senior-machining-process-engineer-r-d-vulcan-elements-research-triangle-park-gd1d8f19kfj4'
type: 'job'
last_seen: '2026-09-06'
---

# Senior Machining Process Engineer – R&D at Vulcan Elements

- **Company:** Vulcan Elements
- **Location:** Research Triangle Park, NC
- **Posted:** 2026-07-08
- **Last confirmed live:** 2026-09-06
- **Apply:** https://job-boards.greenhouse.io/vulcanelements/jobs/5302777008

## 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 Transparency.

Sintered NdFeB magnets are a challenge to machine and finish: hard, brittle, chip-prone, corrosion-sensitive. 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.

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.

## Responsibilities

Process Characterization, Metrology & Quality

- Metrology, surface finish, and inspection methods
- Establish SPC and capability baselines and drive loss/defect rates down with data

Equipment Specification & New Process Introduction (NPI)

- Evaluate, specify, and justify new machining and finishing processes to Vulcan; run vendor trials, define acceptance criteria.
- Document developed processes and hand off validated, capable processes to pilot production — including processes destined for future high-volume magnet factory programs.

Optimization of Existing Machining Processes

- Develop and optimize slicing, grinding, abrasive, tumbling processes
- 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.
- Development of novel tooling and fixturing as needed
- Understand and quantify surface effects on downstream coating adhesion, corrosion, and magnetic performance.

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

We are looking for depth in abrasive machining plus the range to own everything around it:

- Abrasive Machining of Hard/Brittle Materials: Direct experience machining sintered magnets, technical ceramics, carbide, glass, silicon/semiconductor wafers, or similar brittle materials.
- Diamond Tooling: Working knowledge of diamond wire, wheel, and media specification.
- Machine Craft: Comfortable at the machine: setup, alignment, fixturing, troubleshooting vibration and chatter.
- Coolant & Filtration Systems: Practical understanding of coolant chemistry, delivery, filtration technologies, and swarf/sludge handling.
- Statistics & DOE: Fluency in designed experiments, measurement system analysis, SPC, and capability studies.
- Metrology & GD&T: Strong command of GD&T interpretation and precision dimensional/surface metrology at micron scale.
- CAD & Fixture Design: Able to design and iterate workholding, carriers, and handling fixtures (SolidWorks, Fusion 360, or similar).

## Qualifications

- B.S. in Mechanical Engineering, Manufacturing Engineering, Materials Science, or equivalent hands-on experience.
- 5+ years of process engineering experience in machining/finishing.
- Demonstrated ownership of a machining process from development through production release.
- Experience with NdFeB or other permanent magnet materials is a strong plus, but we will gladly teach magnets to someone who deeply knows grinding.

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

Desired Skills

- Experience in semiconductor wafering, optics fabrication, cutting tool manufacturing, or technical ceramics.

Laboratory Safety and PPE Requirements

This role requires strict adherence to all laboratory safety protocols and regulatory guidelines. Employees must consistently wear appropriate personal protective equipment (PPE), including lab coats, safety glasses, gloves, and any additional gear required for specific materials or processes. The position involves working around equipment and procedures that present cut hazards and other physical risks associated with slicing, grinding, and tumbling operations. Team members must follow all established safety rules, use tools and machinery only as trained, and maintain awareness of mechanical pinch points, sharp components, and moving parts.

Employees are expected to maintain a clean and compliant work area, promptly report any unsafe conditions, and complete all required safety training. A strong commitment to maintaining a safe and compliant laboratory environment is essential for success in this role.

## 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

- [Payroll Specialist](https://feeny.ai/job/payroll-specialist-vulcan-elements-research-triangle-park-cgnbgwqzqqss) — Research Triangle Park
- [Senior Materials Scientist](https://feeny.ai/job/senior-materials-scientist-vulcan-elements-research-triangle-park-53n83a0hj1yh) — Research Triangle Park, NC
- [Sr. Manager, Operational Excellence](https://feeny.ai/job/sr-manager-operational-excellence-vulcan-elements-benson-y4aw80sbt401) — Benson, NC
- [Staff Process Engineer](https://feeny.ai/job/staff-process-engineer-vulcan-elements-research-triangle-park-jfs5jqwjdteq) — Research Triangle Park, NC
- [R&D Materials & Process Engineer](https://feeny.ai/job/r-d-materials-process-engineer-vulcan-elements-research-triangle-park-ksmm3yh6bxmy) — Research Triangle Park, NC
- [Controls Engineer](https://feeny.ai/job/controls-engineer-vulcan-elements-research-triangle-park-m1m7tkg7thr1) — Research Triangle Park, NC
- [Safety Specialist](https://feeny.ai/job/safety-specialist-vulcan-elements-benson-d58ksk27rxgj) — Benson, NC
- [Machinist](https://feeny.ai/job/machinist-vulcan-elements-benson-z2y1p4qcfny9) — Benson, NC
- [Manufacturing Engineering Manager](https://feeny.ai/job/manufacturing-engineering-manager-vulcan-elements-research-triangle-park-56h2n366x0pb) — Research Triangle Park, NC
- [Machining Site Lead](https://feeny.ai/job/machining-site-lead-vulcan-elements-benson-m7fnfqdmxg27) — Benson, NC