REalloys is rebuilding the most critical part of the rare earth and magnet supply chain that has been missing in North America for more than two decades: midstream processing. Midstream is where rare earths stop being rocks, powders, or concentrates and become the purified metals, alloys, and magnet materials that power the technologies defining modern life. These steps – monazite cracking, uranium and thorium removal, solvent-extraction separation, oxide purification, metallization, alloying, powder production, and magnet fabrication – are the true bottleneck of the global supply chain, and today more than 90% of this capability exists only in China. Even rare earths mined in the United States are typically shipped overseas for processing, leaving the country dependent on foreign infrastructure for its most strategically important materials. REalloys is reversing this dependence by building the first fully integrated, commercial-scale midstream platform in North America, anchored by an exclusive partnership with the Saskatchewan Research Council (SRC), the only Western facility capable of cracking monazite and removing uranium and thorium at industrial scale. SRC’s zero-liquid-discharge, AI-controlled solvent extraction system – engineered entirely outside China – represents the most advanced rare earth separation technology available in the West, and it has already produced commercial quantities of NdPr metal, a first in North America. This midstream foundation is further strengthened by REalloys’ HF-free metallization technology, which eliminates hydrofluoric acid from oxide-to-fluoride conversion, dramatically improving safety, environmental compliance, oxygen control, and purity while reducing costs and insulating production from Chinese chemical supply chains.
Downstream of SRC, REalloys’ Ohio facility provides the second half of the midstream: domestic alloying, powder production, microstructure engineering, strip casting, hot pressing, spark plasma sintering, and the pilot-scale manufacturing of NdFeB, MnBi, and next-generation SmFe₁₂ magnets. This site is one of the few places in the U.S. capable of producing rare earth metals, advanced magnet powders, and fully formed magnets under one roof. To ensure resilience and long-term stability, REalloys has built the most diversified feedstock portfolio in North America, sourcing material from Hoidas Lake (owned by REalloys), Monazite resource via SRC, St. George’s Araxá project, Tanbreez in Greenland, recycled magnets, wind turbine scrap, e-waste, lamp phosphors, and acid mine drainage recovery. This multi-source strategy eliminates dependence on any single resource and creates the most flexible midstream processing ecosystem in the West.
By establishing this end-to-end midstream capability, REalloys is enabling something the U.S. has lacked for decades: a secure, domestically controlled pathway for producing the rare earth metals and magnets required for defense systems, electric vehicles, wind turbines, industrial automation, consumer electronics, and national infrastructure. Defense readiness depends on magnets for missiles, jets, submarines, radar, electronic warfare, and guidance systems; electrification depends on magnets for EV traction motors and wind turbine generators; robotics, aerospace, and advanced manufacturing rely on high-performance magnet alloys. Without domestic midstream processing, none of this can be onshored. REalloys is not just filling the gap – it is rebuilding the entire industrial foundation needed to support North America’s technological future. For the first time in decades, a fully sovereign rare earth and magnet supply chain is becoming a reality. The midstream revolution has finally begun, and REalloys is leading it.
