Vulcan Elements

Materials Process Engineer - Metals

Research Triangle Park, NCmidAdded today

About this role

Vulcan Elements seeks a Materials Process Engineer to develop and validate computational models simulating fluid dynamics, heat transfer, electromagnetics, and mechanical behavior across rare-earth magnet manufacturing processes. You'll translate simulation insights into process optimization strategies, working with ANSYS, COMSOL, and scripting tools to support product development in defense and aerospace applications.

What you'll do

Build and validate thermal, fluid dynamics, and stress models for manufacturing processes including sintering, heat treatment, and casting
Create multiphysics simulations using ANSYS (Mechanical, Maxwell, Fluent, ROCKY) or COMSOL Multiphysics
Integrate simulation outputs with process data to drive optimization and support experimental campaigns
Design sensitivity studies and failure mode analyses to guide process development
Develop Python/MATLAB scripts for simulation pre/post-processing and automation
Document modeling assumptions, boundary conditions, and validation results per quality system requirements

What they're looking for

ANSYS (Mechanical, Maxwell, ROCKY, Fluent) or COMSOL Multiphysics
Computational Fluid Dynamics (CFD)
Heat transfer and thermal modeling
Mechanical stress and strain analysis
Python or MATLAB scripting
Metal manufacturing process knowledge (sintering, casting, heat treatment)
Multiphysics coupled simulations
Technical communication to cross-functional teams

Benefits

Work on national security-focused rare-earth magnet technology
Serve critical defense, aerospace, and automotive industries
Collaborate with experienced materials and process engineering teams
Research Triangle Park location with access to advanced simulation platforms

Likely interview questions

Walk us through a metal manufacturing process you've modeled—what physics did you include and how did you validate it?
Describe your experience with ANSYS or COMSOL: which modules have you used most, and what was your role in setting up simulations?

How have you used Python or MATLAB to automate or post-process simulation results, and what was the impact?
Tell us about a time you identified a process sensitivity or failure mode through simulation that led to a real manufacturing improvement.
What multiphysics coupling challenges have you encountered, and how did you approach them?
How do you approach validation when experimental data is limited or when simulations don't match reality?
Describe your experience working with cross-functional teams—how do you communicate complex simulation results to non-modeling experts?

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