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, 

ht@usare.com