Facilities
Saskatchewan Research Council (SRC)
REalloys & SRC Partnership
REalloys holds the rights to acquire 80% of the oxides and metals produced at SRC’s facility, with a right of first refusal on the remaining 20%. This agreement secures long‑term supply and positions REalloys at the center of North America’s rare‑earth value chain.
North America’s First Integrated Facility
SRC operates the first and only fully integrated rare‑earth processing, separation, and metal‑making facility in North America. Its end‑to‑end flowsheet spans monazite cracking, uranium and thorium removal, mixed rare‑earth chloride production, solvent‑extraction separation, oxide purification, and rare‑earth metal smelting – all under one licensed, commercial‑scale operation. This capability eliminates the most significant bottleneck in Western supply chains: the lack of a domestic plant able to process monazite, manage radioactive by‑products safely, and produce magnet‑grade oxides and metals.
Independence From China
A defining strength of SRC is its complete independence from Chinese equipment, parts, process materials, and consumables. Every component used in the facility’s design and operation is sourced outside China, with raw materials and consumables coming primarily from North American suppliers. This ensures unmatched geopolitical resilience, supply‑chain assurance, and regulatory compliance for customers seeking a fully non‑Chinese rare‑earth supply pathway.
Proprietary Technology & Compliance
SRC combines proprietary solvent‑extraction technology, advanced automation, and licensed handling of uranium and thorium residues. Together, these capabilities make SRC the only Western alternative to Chinese mid‑stream rare‑earth processing.
| Feature | Description |
|---|---|
| Fully integrated “minerals-to-metals” chain | The facility is designed not only to do ore/concentrate → mixed rare earths (chlorides/carbonates) → separated oxides but also to metal smelting of Nd, Pr, Dy, and Tb alloys. |
| Only North American facility for Uranium & Thorium Removal | SRC has the capability and the permits to crack monazite and remove uranium and thorium at commercial scale, solving the radioactive-materials bottleneck that prevents virtually all other Western rare-earth processors from operating. |
| Proprietary solvent‐extraction (SX) cell technology and automation | SRC developed its own commercial-scale SX cells for REE separation, with AI/automation features to improve equilibration time, throughput and cost. |
| 100% Non-China Sourcing | CEvery component used in fabrication of the equipment and facility is sourced outside China. Additionally, all raw materials and consumable required for Rare Earth oxide and metal production is 100% sourced from non-Chinese sources, and mostly from North America. |
| First commercial‐scale REE metal production in North America | The facility achieved production of rare-earth metals (NdPr etc) at commercial scale (Summer 2024) in Saskatchewan – making it the first jurisdiction in North America to do so. |
| Feedstock and capacity design | The facility is designed to process ~3,000 tpy of monazite concentrate (≥80% basis) into mixed RE chlorides/oxides, then separate lanthanum/cerium, medium/heavy REE mixture, and Nd/Pr metal alloys (~500 t per year) on ramp up. |
| Environmental / ESG commitments | SRC has developed a process that requires zero liquid discharge, full recycling of aqueous streams, advanced tailings & waste management, consistent with high ESG/permit standards in Saskatchewan. |
| Geopolitical/strategic supply-chain location | Located in a stable mining jurisdiction (Saskatchewan, Canada), offering a Western alternative to dominant processing in China, thus shortening, diversifying, de-risking supply chains. |
Facilities
Ohio Advanced R&D and Pilot Production
Strengthening the U.S. Magnet Supply Chain
REalloys has acquired PMT Critical Metals of Ohio, a company with decades of expertise in alloy design, engineered powders, and scaling metallurgical processes from lab to full production. These capabilities directly enable a fully domestic, vertically integrated magnet supply chain – reducing reliance on China and closing the largest gap in U.S. critical‑materials infrastructure: rare‑earth metal conversion and magnet manufacturing.
Innovation & Next‑Generation Magnet Development
PMT Critical Metals brings advanced technology platforms, a strong IP portfolio, and world‑class engineering talent. Together, these assets provide the ability not only to manufacture magnets domestically, but also to pioneer the next generation of low‑ and no‑heavy‑rare‑earth magnets. This positions the United States as a global leader in magnet R&D and production for defense, electric vehicles, wind energy, and aerospace.
Deep Materials Science Expertise
The facility and team contribute decades of materials science, metallurgical processing, and powder‑based manufacturing knowledge – capabilities largely absent in the U.S. today. Their leadership spans advanced metal powders, reactive alloys, grain‑boundary engineering, and high‑performance material systems, all foundational to modern magnet manufacturing.
Core Competencies in Rare‑Earth Processing
PMT’s core strengths – thermochemical processing, alloy design, controlled microstructure evolution, and precision powder consolidation – map directly onto the most technically challenging parts of the rare‑earth value chain. These include metallization, powder production, oxygen‑controlled processing, strip‑cast flake production, high‑temperature consolidation, and advanced magnet development.
Proven Production Capabilities
The facility has already demonstrated production of high‑purity Dy, Nd, Nd‑Dy, Mg‑Nd, Gd, Sm, and Sc metals, as well as NdFeB and MnBi magnets. With these proven capabilities, PMT Critical Metals is uniquely positioned to deliver both immediate domestic magnet production and long‑term innovation in next‑generation magnet technologies.
Facilities
Hoidas Lake Mine
A Unique Rare Earth Deposit
Hoidas Lake is one of the few rare earth deposits in North America containing both light rare earth elements (Nd, Pr) and meaningful concentrations of heavy rare earth elements (Dy, Tb). These materials are critical for high‑temperature NdFeB magnets used in electric vehicles, wind turbines, and defense systems. Unlike most North American deposits that are largely LREE‑only, Hoidas Lake’s allanite‑apatite mineralogy provides a rare domestic pathway to HREE supply – resources that today are sourced almost entirely from China.
Strategic Location Near SRC
Located in Saskatchewan, Hoidas Lake sits close to the Saskatchewan Research Council’s (SRC) newly built rare‑earth separation facility – the first integrated LREE + HREE separation plant in North America using 100% non‑Chinese equipment and consumables. This proximity provides Hoidas Lake with a uniquely direct route to commercial rare‑earth oxide production, avoiding the permitting, radiological, and processing challenges that often constrain monazite‑based projects. Its mineralogy is also more environmentally manageable, enabling simplified cracking and HF‑free processing flowsheets.
Supporting North American Supply Chain Security
As the U.S. and Canada prioritize supply‑chain resilience for EVs, renewable energy, and defense, Hoidas Lake represents an ideal medium‑scale, geopolitically safe feedstock. The deposit can support 3,000–5,000 tonnes per year of magnet manufacturing capacity while meeting specialty heavy‑rare‑earth needs.
Alignment With Policy & Industry Needs
Hoidas Lake is exactly the type of project that aligns with U.S.–Canada critical mineral agreements, DPA Title III funding priorities, and OEM/defense requirements for non‑Chinese magnet materials. In short, it is one of the very few deposits capable of anchoring a fully North American rare‑earth value chain – from ore to metal to magnet.
Facilities
U.S Metallization Facility – 3,000 tons/year
Closing the Supply Chain Gap
REalloys is building North America’s first large‑scale, fully integrated rare earth metallization facility. Designed to convert rare earth oxides into 3,000 tons per year of high‑purity metals, the plant forms the core of REalloys’ mine‑to‑magnet strategy and addresses one of the most critical gaps in the Western rare earth supply chain.
Advanced, Clean Technology
The facility is engineered to produce Nd, Pr, NdPr alloy, Dy, Tb, Sm, Gd, Y, and other strategic metals. Using REalloys’ proprietary HF‑free reduction technology, it delivers cleaner, safer, and higher‑yield oxide‑to‑metal conversion compared to traditional hydrofluoric‑acid‑based processes. Advanced reaction furnaces, vacuum distillation systems, refining lines, alloy production, and downstream powder preparation ensure magnet‑grade purity for defense, EV, wind, aerospace, and industrial customers.
Fully Domestic & Defense‑Compliant
Designed as a defense‑compliant metallization hub, the facility integrates seamlessly with the Saskatchewan Research Council’s oxide production streams and REalloys’ Ohio alloying and magnet manufacturing operations. Together, these assets create a complete end‑to‑end U.S. supply chain for high‑performance permanent magnets.
Restoring North American Capability
With capacity to support 10,000 tons per year of NdFeB magnets, this plant positions REalloys as the leading domestic supplier of rare earth metals and magnet materials. It restores a metallization capability that disappeared from North America decades ago – re‑establishing sovereign strength in critical materials for the industries of the future.
Facilities
U.S. Magnet Manufacturing Facility – 10,000 tons/year
Scaling Magnet Manufacturing in North America
REalloys is building one of the world’s largest and most advanced NdFeB magnet production facilities. Starting at 3,000 tons per year and scaling to 10,000 tons, the plant will deliver high‑performance permanent magnets for electric vehicles, wind turbines, robotics, medical systems, and defense platforms. This expansion transforms REalloys’ pilot‑commercial plant into the first giga‑scale magnet factory in North America.
Fully Integrated Supply Chain
Powered by REalloys’ end‑to‑end supply chain – from diversified rare earth feedstock to oxide production, HF‑free metallization, alloying, powder production, and final magnet machining – the facility provides the United States and its allies with a stable, industrial‑scale source of magnet materials.
Advanced Manufacturing Technology
The plant incorporates state‑of‑the‑art systems including strip‑casting lines, low‑oxygen powder production, automated jet milling, field alignment presses, high‑temperature sintering furnaces, hot‑press/hot‑deformation systems, and precision machining and coating lines. These capabilities ensure throughput, consistency, and magnet performance equal to or exceeding global benchmarks.
Production Capacity & Applications
At full scale, the facility can supply magnets for:
Defense‑Grade Quality & Innovation
Every stage of production is designed to meet defense‑grade standards and U.S./Canadian sourcing requirements. Automation, AI‑enabled process control, and rigorous metrology enable REalloys to produce sintered NdFeB magnets with exceptional coercivity, energy product, and temperature stability – including high‑temperature and heavy‑rare‑earth‑free grades optimized for EV traction motors and next‑generation drive systems.
Anchoring the Western Supply Chain
By scaling to 10,000 tons per year, REalloys becomes the largest producer of NdFeB magnets in the Western Hemisphere. This facility anchors North America’s magnet supply chain, reduces dependence on foreign manufacturers, and establishes a resilient foundation for electrification, clean energy, industrial automation, and national security.
Cornerstone of the Ecosystem
REalloys’ giga‑scale facility positions the company as the cornerstone of North America’s rare earth and magnet manufacturing ecosystem – delivering the capacity, reliability, and technological leadership required for the next generation of energy, transportation, and defense infrastructure.
