Europe Launches New Projects to Secure Green Tech Magnet Supplies
European researchers are launching two major initiatives to reduce the continent's dependence on foreign supplies of rare earth elements used in green technologies. By recycling old components and developing new magnet types, these projects aim to secure the supply chains for electric vehicles and wind turbines. This shift is critical because current production is heavily concentrated in China.
- China refines 91% of the world's rare earths used in magnets, according to the International Energy Agency.
- The MAGELLAN project has already produced high-performance magnets containing 25% recycled material by weight, per Cyprus Mail.
- The MagNEO project aims to demonstrate industrial-scale 3D-printed magnet designs by the year 2028.
Why is Europe worried about magnet supplies?
The clean energy transition relies on permanent magnets to make motors smaller, lighter, and more efficient. These magnets are vital for electric car traction motors and wind turbine generators. Without a steady supply, Europe faces significant risks to its climate goals and industrial stability.
A massive concentration of the supply chain in China creates a vulnerability. The International Energy Agency reported that China mines 60% of the world's rare earths for magnets and manufactures 94% of all permanent magnets. This dominance exposes European manufacturers to potential trade restrictions and sudden supply disruptions.
Dependence is a major hurdle. High concentration means any geopolitical tension could halt production of essential green technologies. This reality is driving the push for advanced materials that either reuse existing resources or bypass rare earths entirely.
Can recycling old magnets work?
Recycling aims to create a circular economy by recovering valuable neodymium and other rare earth elements from discarded products. The MAGELLAN project is currently leading this effort by rethinking the entire life cycle of a magnet, from its initial design to its eventual dismantling.
Researchers are already testing how to extract magnets from the rotors of electric bikes, scooters, and end-of-life cars. While the supply of scrap is currently low, a massive wave of waste is coming. Electric cars typically last between 15 and 20 years, while offshore wind turbines can operate for about 30 years.
The scale of future waste is significant. According to European Commission reports, the waste flow will increase sharply within the next decade. This will make the recovery of these materials more economically viable for European industry.
"Within the decade, [...] recovering and recycling these rare earths will be more economically viable. You will still have some premium compared to business as usual, but there will be a strategic pay-off."
Alexandre Damiens, magnets and rare earths expert at Orano
How much could recycled magnets supply?
Recycling is not expected to replace all mining immediately, but it can provide a meaningful cushion for the market. Researchers have modeled the potential impact of a single large-scale facility on the European market.
A manufacturing facility with an annual capacity of 2,000 tonnes could provide roughly 10% of the projected European electric vehicle traction motor market by 2040. This would represent about 4% of the broader European permanent magnet market.
The work also builds essential industrial expertise. By using a pilot line in Grenoble, the project helps European manufacturers learn how to incorporate secondary materials into high-performance products. This creates a new generation of skilled manufacturers capable of competing globally.
Is it possible to build magnets without rare earths?
The MagNEO project is investigating whether engineers can bypass rare earths by using different materials altogether. The team is focusing on AlNiCo magnets, which are iron-based alloys containing aluminium, nickel, and cobalt.
These materials are not a new discovery. They have been used for decades in applications like guitar pickups and sensors. However, the MagNEO team is using modern techniques like 3D printing to rethink how they are used in heavy-duty motors.
3D printing allows for complex internal structures. These designs might help the magnets perform better in specific tasks. This approach seeks to tailor the material to the machine, rather than relying on the raw power of rare earths.
"AlNiCo magnets are not new. They have been developed since the Second World War. But not much has happened with their development in the last few decades."
Spyros Diplas, SINTEF expert
Will these alternatives be as strong?
There is a physical limit to how much energy these alternative magnets can provide. AlNiCo magnets cannot match the magnetic energy density of rare earth magnets, which is the amount of energy delivered in a specific volume.
Researchers are not trying to replicate the exact performance of rare earth magnets. Instead, they are looking at how to combine weaker magnets with better motor designs. This could make them viable for heat pumps, ship propulsion, and certain wind turbines.
The strategy is to change the motor to fit the magnet. By altering the design of the motor, the limitations of the AlNiCo material can be compensated for. This makes the technology a practical alternative rather than a direct replacement.
"It’s not sensible to believe that we’re going to get rare earth magnet performance with AlNiCo, or with any other magnets. It’s physics – there are physical limitations."
Spyros Diplas, SINTEF expert
What is the timeline for these technologies?
Both projects are working toward specific milestones to prove their commercial and industrial potential. The focus is moving from laboratory experiments to large-scale demonstrations of how these materials behave in real-world systems.
The MAGELLAN team is currently moving toward incorporating recycled material into their pilot line. Their next major goal is to demonstrate how these recycled magnets actually function inside an electric motor. This will prove that "secondary" materials can meet high-performance standards.
The MagNEO project has a deadline of 2028. By the end of that year, the team aims to demonstrate that at least two magnet designs can be 3D-printed at an industrial scale. These prototypes will undergo testing in selected systems and computer simulations of complete motors.
Background: The Rare Earth Challenge
To understand this shift, one must look at the current landscape of green technology. Rare earth elements, specifically neodymium, are the backbone of modern high-efficiency motors. Because they are difficult to mine and process, the supply chain is highly sensitive to political changes.
Historically, the world has relied on a centralized supply model. This model is now being challenged by the European Union's push for "advanced materials." These are engineered substances designed to improve performance in strategic areas like defense, energy, and transport.
The transition from a centralized supply to a circular or alternative supply is a long-term goal. It involves shifting from a "take-make-waste" model to one where materials are recovered from the millions of electric vehicles and wind turbines that will eventually retire.
What happens next?
The immediate focus remains on the pilot testing of recycled magnets in motors. In the coming years, the industry will watch for the results of the MagNEO 3D-printing demonstrations. If successful, these could provide a blueprint for a new type of magnet manufacturing in Europe.
The ultimate goal is to see these technologies reach industrial scale by the late 2020s. This would coincide with the first major wave of retired electric vehicles and wind turbines, creating a steady stream of raw materials for the European market.
FAQ
Why are rare earth magnets important for the environment?
They allow electric motors and wind turbines to be smaller and more efficient, which is necessary for a clean energy transition.
Can we replace rare earths entirely?
While some materials like AlNiCo are being developed, they cannot match the raw power of rare earths, so they will likely be used in specific, redesigned applications.
How does recycling help Europe's security?
Recycling creates a local supply of materials from old cars and turbines, reducing the need to import everything from countries like China.
