Process Development Engineer

Process Development Engineer Job ID 134148 Job Type Direct Hire Industry Defense Location Ft. Worth, Texas, United States A Talascend client is seeking an experienced Process Development Engineer for a direct hire role based in Fort Worth, TX. Please note role is fully onsite 5 days per week.

Position Overview:

The company is seeking a hands-on Senior Engineer to join the Magnet Technology group to support development technologies for advanced manufacturing to produce high-performance rare earth permanent magnets. The Senior Engineer will specialize in hands-on experimental development efforts related to front-end magnet-making processes, including but not limited to strip casting, powder processing, pressing, and sintering. Responsibilities include designing custom experimental setups, running experimental campaigns on pilot-scale equipment, and materials characterization using techniques such as magnetometry, microscopy, and chemical analysis. In addition, the Senior Engineer will provide technical leadership to junior engineers and technicians, drive cross-functional collaboration with production teams, and play a key role in setting technical directions for future process improvements. The role encompasses a broad range of initiatives, from designing materials for optimum performance to developing and optimizing manufacturing processes. This is a rare opportunity to play a key role in returning an essential manufacturing capability to the USA.

Position Responsibilities:

Lead experimental projects, overseeing project planning, execution, and delivery of scalable new materials and processes for rare-earth permanent magnets Design and conduct experiments to optimize new materials and processes for rare-earth permanent magnets Leverage materials characterization techniques including SEM, XRD, particle size analysis, etc. to suggest actionable process improvements Collaborate with production teams to scale processes from pilot to manufacturing operations Mentor technicians and engineers to ensure high-quality execution of experimental trials and data collection, providing technical guidance in metallurgical materials, and fostering a culture of continuous learning and professional development Lead the generation of technical reports and SOPs, document and communicate findings, and build team knowledge of current and future magnet prototyping Work closely with EHS to ensure that all work is done to ensure world-class health and safety, and full compliance with relevant environmental regulations Other duties as assigned

Basic Qualifications:

Master's or Ph.D. in Materials Science & Engineering, Metallurgy, Mechanical Engineering, or related field 5+ years of experience in manufacturing or R D demonstrating successful process development across metals, ceramics or related systems Strong knowledge and experience with process development in areas such as casting, powder metallurgy, pressing, or sintering Proficiency in materials characterization techniques such as XRD, SEM, and particle size analysis Demonstrated ability to design and execute experiments, analyze data, and draw actionable conclusions Excellent written and verbal communication skills

Desired Qualities:

Experience with manufacturing of rare earth materials and permanent magnets Strong troubleshooting skills with manufacturing equipment and process control Experience leading technical development projects, with the ability to prioritize and manage multiple concurrent projects Strong skills in analyzing experimental data using tools such as Python, MATLAB, or statistical software to draw actionable insights and guide decision-making Lifelong learner able and enthusiastic to apply existing skills and experiences to new problems We thank all applicants for their interest. However, only those qualified individuals who closely meet the qualifications of the position will be contacted. The details of the position are only a summary, other duties may be assigned as necessary. Background Check and Drug Screen may be required.