---
title: 'Senior Materials Scientist at Vulcan Elements'
canonical: 'https://feeny.ai/job/senior-materials-scientist-vulcan-elements-research-triangle-park-53n83a0hj1yh'
type: 'job'
last_seen: '2026-09-06'
---

# Senior Materials Scientist at Vulcan Elements

- **Company:** Vulcan Elements
- **Location:** Research Triangle Park, NC
- **Posted:** 2026-09-02
- **Last confirmed live:** 2026-09-06
- **Apply:** https://job-boards.greenhouse.io/vulcanelements/jobs/5406596008

## 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 the Senior Material Scientist you will own the science connecting the metallic coatings that protect them from corrosion and the characterization work that proves it. This is an R&D role based at our Research Triangle Park lab, working in direct support of our Benson, NC manufacturing facility: you'll develop and qualify processes in the lab and on pilot-scale equipment, interface with external suppliers then hand off specifications the Benson production team runs at scale. You'll own key external coating supplier relationships. This is a hands-on, individual-contributor role with real influence over how a brand-new production facility is built and qualified.

## Responsibilities

- Develop, qualify, and optimize protective metallic, passivation, or polymer coatings (e.g., electroplated Ni, Zn, or Al-based systems, PVD/sputtered layers) for sintered NdFeB magnets to meet corrosion, adhesion, and thermal-performance specifications.
- Design and run coating process experiments and correlate process variables to coating quality, adhesion strength, and salt-spray/humidity performance.
- Perform materials characterization and failure analysis using SEM/EDS, XRD, optical microscopy, coating-thickness and adhesion testing, and accelerated corrosion testing (e.g., ASTM B117 salt spray) across both R&D and production samples.
- Manage relationships with external coating suppliers and toll processors: qualify new vendors, audit their processes and quality systems, and coordinate outsourced coating runs to support production timelines and second-source strategy.
- Partner with the powder metallurgy and process engineering teams to understand how upstream variables shape the finish and microstructure that coating performance and magnetic properties depend on.
- Lead root-cause investigations for coating defects, corrosion failures, and quality escapes, and drive corrective and preventive actions through to closure, whether the issue originates in-house or at a supplier.
- Author and maintain rigorous, operator-ready process documentation, test protocols, and supplier specifications that support scale-up and quality systems.
- Present experimental results, process recommendations, and risk assessments to cross-functional partners and leadership.
- Provide technical mentorship to junior engineers and lab technicians on coatings and materials-testing best practices.

## Qualifications

- Ph.D. or Master's degree in Materials Science, Metallurgical Engineering, Chemistry, or a related technical field.
- 3+ years of hands-on experience in metallic coatings, surface finishing, or corrosion protection in an industrial or manufacturing R&D setting.
- Working proficiency with materials characterization techniques: SEM/EDS, XRD, optical microscopy, and coating thickness/adhesion testing.
- Familiarity with structured failure-analysis methodology.
- Solid grounding in design of experiments (DOE) and statistical analysis of process and test data.
- Strong technical writing and cross-functional communication skills.
- Experience managing external suppliers or contract processors — qualifying new vendors, auditing their processes and quality systems, and coordinating outsourced work against a schedule.

U.S. Person status required, due to access to export-controlled information.

Desired Skills

- Direct experience with rare-earth permanent magnets (NdFeB) and their corrosion behavior or protective coatings.
- Exposure to powder-metallurgy processing (pressing, vacuum sintering) and its downstream effect on coating performance.
- Proficiency with a data-analysis tool such as Python, MATLAB, or JMP/Minitab for manufacturing and quality datasets.
- Familiarity with ISO 9001 or IATF 16949 quality management systems.
- Experience in a startup or fast-scaling manufacturing environment.

Laboratory Safety and PPE Requirements

This position requires strict adherence to 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 procedures or chemical handling. The role involves working with potentially hazardous materials, equipment, and processes, and team members must follow all established safety rules, maintain a clean and compliant work area, and promptly report any unsafe conditions. The individual must be able to complete required training, apply proper safety practices, and demonstrate a strong commitment to maintaining a safe laboratory 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
- [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
- [Buyer](https://feeny.ai/job/buyer-vulcan-elements-research-triangle-park-wymzztx1dfn6) — Research Triangle Park, NC