In a groundbreaking advancement for sustainable manufacturing and materials science, a collaborative project involving several European institutions has successfully demonstrated the industrial-scale processing of recycled neodymium-iron-boron (NdFeB) powders into high-performance magnets. This achievement represents a significant leap forward in the circular economy for rare earth elements, pivotal components in modern-day technologies. The process, developed and validated through meticulous engineering and rigorous testing, underscores a viable pathway toward reducing dependence on primary raw material sources while enhancing Europe’s strategic autonomy in magnet production.
The core of the development was the supply of eight kilograms of recycled NdFeB powder, sourced from the University of Birmingham, a leading hub in rare earth research. This finely processed powder was entrusted to Kolektor Mobility, an engineering firm based in Ljubljana, Slovenia, known for its innovative approach in materials compounding and manufacturing processes. The team at Kolektor Mobility engineered a robust compounding and injection molding protocol, optimized to handle the complexities of recycled powder, which often presents challenges related to particle size distribution, chemical homogeneity, and magnetic phase integrity.
The engineering challenge was not trivial. Recycled NdFeB powders tend to exhibit variable qualities due to prior usage and the inherent complexities of rare earth recycling methods. Kolektor’s process innovation included precise tuning of temperature profiles, injection pressures, and cycle times, coupled with a new sprue overflow design. This design innovation ensured the elimination of defects such as voids and incomplete filling, which are common pitfalls in injection molding of magnetic powders. The result was a consistent production of magnets with dimensional stability and reliable magnetic properties.
Following the successful molding process, fifty individual magnets were manufactured for a demonstration project led by COPRECI, a reputable domestic appliance manufacturer located in Gipuzkoa, Spain. COPRECI’s application-oriented expertise provided a real-world platform to incorporate these recycled magnets into appliance components, testing not only their physical form but operational performance within practical devices. This phase was critical in translating laboratory success into applied industrial validation.
The manufactured magnets underwent a comprehensive validation regimen. Dimensional analysis using high-precision metrology tools confirmed that the magnets met strict geometric tolerances required for appliance integration. Complementing this, computed tomography (CT) inspections provided detailed internal imaging to detect any voids or microstructural anomalies invisible to surface inspection. These assessments ensured that the physical integrity of the magnets was uncompromised during processing.
Beyond physical characterization, magnetisation procedures aimed to achieve optimal alignment of magnetic domains within the NdFeB material. Subsequent magnetic field mapping quantified the magnetic flux density across the magnet surfaces, confirming uniformity and performance consistency. Achieving controlled magnetic properties is crucial because magnet strength and field distribution directly influence the efficiency and reliability of motors and other electromagnetic devices in which these magnets are deployed.
The initial testing underscored that recycled NdFeB materials could meet or exceed the stringent application requirements imposed by industry standards. This finding was pivotal, as it dispelled lingering skepticism about the feasibility of recycled magnets serving as functional, high-quality components in demanding technological applications. After passing these validations, the magnets were delivered to COPRECI for full integration into prototype appliance units, paving the way for further product-level assessments.
Further mechanical and durability testing is being conducted at Fraunhofer LBF in Darmstadt, Germany, an applied research organization renowned for its advanced materials testing capabilities. These trials extend beyond magnetic properties to evaluate mechanical robustness, wear resistance, and long-term durability under operational stresses, factors that are critical in ensuring that recycled magnets can withstand lifecycle demands akin to those manufactured from virgin materials.
This entire milestone marks a decisive step in demonstrating that recycled rare earth elements are not only recyclable but can be reintroduced into the supply chain at a scale and quality compatible with industrial manufacturing demands. By establishing streamlined processing methods that integrate seamlessly with existing technologies, the project contributes fundamentally to closing the material loop, an essential aspect of sustainability and resource resilience.
Ana Drmota Petrič, a leading researcher at Kolektor, articulated the broader significance of the work, stressing that the capacity to turn recycled rare earth materials into functional magnet components using industrial processes is vital. She emphasized that this breakthrough advances Europe’s ambition to build circular value chains for permanent magnets, which hold critical importance across sectors such as electric vehicles, renewable energy technologies, and household appliances.
Permanent magnets based on rare earth elements like NdFeB are indispensable in today’s technological landscape due to their exceptional energy density and magnetic strength. However, primary raw material extraction faces geopolitical, environmental, and supply chain constraints, underscoring the pressing need for sustainable alternatives. Despite their importance, recycling rates for rare earth magnets remain remarkably low, with much material ending up in waste streams, lost to industrial reuse opportunities.
The HARMONY project, under which this work is progressing, seeks to address this challenge by developing end-to-end solutions that encompass collection, recycling, processing, and magnet fabrication. By enhancing practical recycling and manufacturing routes, the initiative aims to reduce European dependence on primary imports, foster strategic material sovereignty, and build more resilient, environmentally responsible supply chains.
This success story sets a precedent that could catalyze widespread adoption of recycled materials in magnet manufacturing, thereby helping to mitigate the environmental footprint of resource extraction and contribute to the circular economy. As industrialization of recycled NdFeB magnet production gathers momentum, it is poised to transform the rare earth magnet supply ecosystem fundamentally, promoting sustainability without compromising performance.
In summary, the integration of recycled NdFeB powders into functional magnets showcases the convergence of materials science innovation, industrial engineering, and sustainability goals. The demonstrated processes and validation protocols ensure that recycled magnets can fulfill technical and operational requirements across diverse applications. This accomplishment paves the way for future scaling and commercialization efforts aimed at embedding circularity into magnet supply chains on a global scale.
Subject of Research:
Recycling and industrial processing of neodymium-iron-boron (NdFeB) powders for production of functional permanent magnets.
Article Title:
Industrial-Scale Manufacturing of Functional Magnets from Recycled Rare Earth Materials Marks Breakthrough for Circular Economy.
News Publication Date:
September 2025.
Web References:
https://mediasvc.eurekalert.org/Api/v1/Multimedia/e27f7cd1-a657-4784-851e-0a18a251e28e/Rendition/low-res/Content/Public
Image Credits:
Copreci
Keywords
Recycled NdFeB magnets, rare earth recycling, permanent magnets, injection molding, magnetic materials, circular economy, sustainability, magnet processing, materials engineering, European rare earth supply chain, sustainable manufacturing, HARMONY project
