---
title: 'Senior Materials & Process Engineer - Powder Metallurgy at Vulcan Elements'
canonical: 'https://feeny.ai/job/senior-materials-process-engineer-powder-metallurgy-vulcan-elements-research-5e42hvts6a3n'
type: 'job'
last_seen: '2026-09-06'
---

# Senior Materials & Process Engineer - Powder Metallurgy 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/5309586008

## 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.

As a Senior/Staff Materials and Process Engineer, you will serve as the technical lead for the end-to-end powder metallurgy manufacturing process—spanning powder processing, advanced compaction, and thermal treatment. You will be responsible for optimizing current production lines, scaling new NdFeB magnet formulations, and troubleshooting complex materials anomalies. This role bridges the gap between R&D and high-volume production, ensuring maximum magnetic performance, microstructural integrity, and manufacturing yield. This is a high-impact, high-ownership role requiring deep technical expertise and leadership.

## Responsibilities

- Own and optimize the powder metallurgy pipeline, including hydrogen decrepitation, jet milling, pressing and compaction, vacuum sintering, and post-sinter heat treatments.
- Correlate process variables to magnetic properties, microstructure, and part quality.
- Lead root-cause failure analyses for sample defects and implement corrective actions.
- Transition new alloy compositions from pilot scale to robust, high-volume production.
- Define technical specifications and partner with Manufacturing team for selection and commissioning of next-generation manufacturing equipment.

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

## Qualifications

- Bachelor’s, Master’s, or Ph.D. in Materials Science, Metallurgical Engineering, Chemical Engineering, or a related technical discipline.
- 8+ years of hands-on engineering experience in powder metallurgy processing (industrial manufacturing setting preferred).
- Experience with reactive metal powder processing, protective inert atmospheres , vacuum thermal processing, and advanced sintering kinetics.
- Experience with materials characterization and analytical techniques such as SEM, XRD, TGA/DSC
- Strong experience in design of experiments, statistical processing, and leading research efforts

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

## Preferred Qualifications

- Direct experience in the manufacturing of sintered NdFeB permanent magnets and grain boundary diffusion processes.
- Strong proficiency in evaluating magnetic materials properties and interpreting microstructural data.
- Experience utilizing data analysis tools (such as Python, MATLAB, or JMP) to analyze manufacturing quality datasets or automate performance mapping.
- Familiarity with ISO 9001 or IATF 16949 quality management standards.

Physical and Environmental Requirements

The position requires regular presence on the production floor and the ability to navigate all areas of the facility. Candidates must be able to climb stairs, stand and walk for extended periods, and work in environments that may be hot, humid, or noisy. The role also requires the use of personal protective equipment, including respirators, and adherence to all applicable safety policies, procedures, and regulatory requirements. Employees must be able to complete required fit testing, wear appropriate PPE for the duration of assigned tasks, and respond safely to changing conditions within the production environment.

## 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