Staff Mechanical Engineer

vulcanelements · Research Triangle Park, NC · Durham, North Carolina, United States

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 Staff Mechanical Engineer, you will contribute to the full lifecycle of a massive 1 million square foot manufacturing facility expansion—focusing on the custom, in-house design and development of specialized machinery. You will be responsible for translating complex pilot-line processes into fully realized, custom-engineered production equipment. This is a high-impact, high-ownership role requiring deep mechanical and electrical design expertise.  Responsibilities  <ul> <li>Lead the ground-up mechanical and electrical design of custom, proprietary manufacturing equipment tailored to our unique magnet production needs. </li> <li>Work closely with local fabrication shops and machine shops to turn your digital designs into physical hardware. Source components, manage lead times, and oversee quality during the build process. </li> <li>Provide active, on-the-floor support during the assembly, wiring, and initial testing of designed equipment, quickly troubleshooting fitment or functional issues. </li> <li>Conduct rigorous stress analysis (FEA), thermal analysis, and fluid flow simulations (CFD) to ensure custom machinery can withstand aggressive industrial environments. </li> <li>Work closely with cross-functional teams (Process, Quality, and Operations) to gather feedback, conduct design reviews, and incorporate DFM principles to ensure equipment is easy to build, operate, and maintain. </li> <li>Ensure all custom-designed equipment complies with rigorous safety, environmental, and ergonomics standards before it hits the production floor. </li> <li>This position will require some interaction and local travel to fabrication shops to review builds and support equipment development (estimated at <10% travel). </li> </ul> You will also be responsible for developing, reviewing, or managing the following deliverables:  <ul> <li>Detailed 2D manufacturing drawings, complex 3D CAD assemblies, Electrical Drawings, Pneumatic Drawings, and highly accurate tolerance stack-up analyses. </li> <li>Stress Analysis reports, Thermal Analysis models, Fluid Flow simulations, and core Electrical & Pneumatic Calculations. </li> <li>Risk Assessments, Ergonomic Assessments, and equipment-level PFMEA inputs. </li> <li&g

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