R&D Process Engineering Intern (Summer 2027)

Position Overview

The R&D Process Engineering Intern will support research, development, and pilot-scale activities focused on rare earth extraction, separation, and purification. This hands-on internship provides exposure to laboratory experimentation, process development, data analysis, and pilot plant operations within a fast-paced rare earth processing environment. This is an onsite position based in the Company’s laboratory in Wheat Ridge, Colorado.

Key Responsibilities

• Support laboratory and pilot-scale experiments related to rare earth extraction, separation, and purification.
• Assist with experimental design, sample preparation, testing, data collection, and analysis.
• Support pilot plant operations, including equipment setup, testing, monitoring, and troubleshooting.
• Perform mass balance calculations and analyze process data to evaluate recovery, efficiency, and product quality.
• Assist with SOPs, test plans, technical reports, and other process documentation.
• Collaborate with engineers, technicians, and operations personnel to support process development and scale-up.
• Follow established safety, quality, and environmental procedures.

Minimum Qualifications

• Currently pursuing a bachelor’s or master’s degree in Chemical Engineering, Metallurgical Engineering, Materials Science, Chemistry, or a related technical field.
• Relevant coursework in chemistry, metallurgy, chemical processing, mineral processing, or related disciplines.
• Strong analytical and problem-solving skills with an interest in hands-on technical work.
• Ability to accurately collect, analyze, and communicate technical information.
• Strong communication and collaboration skills.

Preferred Qualifications

• Academic, research, project, or internship experience related to hydrometallurgy, extractive metallurgy, mineral processing, or chemical processing.
• Experience with laboratory equipment, experimental methods, pilot-scale systems, or engineering/data analysis tools.
• Familiarity with mass balances, process flowsheets, or process data analysis.

Work Environment

The work environment will be a mix of a typical office environment and a lab environment.

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

The above statements are intended to describe the general nature and level of work being performed by people assigned to this job. They are not intended to be an exhaustive list of all responsibilities, duties, skills required of personnel so classified. The reporting relationship may not reflect the most recent changes to the corporate reporting structure.

USA Rare Earth proudly supports Equal Employment Opportunities

USA Rare Earth's policy is to provide equal employment opportunities to all applicants and will provide reasonable accommodations according to applicable federal, state, and/or local laws.

For assistance applying for employment through this site due to disability, please contact Human Resources, hr@usare.com, to discuss reasonable accommodations.

Who we are:

We are on a mission to become a leading supplier of critical materials that enable the green energy and technology revolution. Our materials and technologies are required for the electric vehicle, green energy, consumer electronics, and defense industries, and our battery grade lithium and tech metals are needed for chipsets, semiconductors, and 5G.

We have a substantial interest in the Round Top, Heavy Rare Earth, Lithium and Critical Minerals deposit in West Texas. We have also developed the United States’ first rare earth and critical minerals processing facility and we own the only scalable, sintered neo-magnet manufacturing system in the Western Hemisphere. By developing this fully integrated, US-based “mine-to-magnet” critical mineral supply chain, we are poised to become the leading domestic supplier to these industries.

What you can expect:

At USA Rare Earth, we are pioneers and problem solvers, technologists and team players. Together, we:

Build Solutions: If our task was a simple one, it would already be done. We are creative and solution-oriented, and we think outside the box to solve important problems. We know that a range of expertise and technologies is needed for success, and we work across sectors and alongside customers to deliver world-class solutions in sustainable ways.

Deliver Quality: When we do things, we do them well. We believe that top-tier quality leads to industry competitiveness and we hold ourselves to the highest quality standards. We move fast when executing, but safety, quality, and excellence always come first.

Lead responsibly: We have a responsibility to the planet, our consumers, our country, and each other. We put safety at the center of all we do, take accountability for our actions, incorporate sustainable practices in our processes and act with the financial best interest of our investors and consumers in mind.

Win Together: Establishing a rare earth magnet supply chain is a big undertaking – and getting there is a team effort. We communicate openly, work together and challenge each other in pursuit of our goals. With every step we take we learn and get better.