Rarearth is creating and industrialising the first integrated process that, starting from electronic waste, completely recovers the NdFeB magnetic alloy to produce new magnets completely preserving the magnetic properties. We demonstrated the production of bonded NdFeB magnets, suitable for the more demanding applications, and obtained breakthroughs also for the production of sintered magnets. The process we developed is sustainable economically and environmentally: our cost is competitive with magnets from virgin raw materials, compared to them our CO2-eq emissions are down by 80% and water consumption is almost eliminated. Furthermore, we developed the first recyclable resin for bonded magnets. Even among competing start-ups, no one was able to develop a profitable process starting from the dismantling up to new magnets production. Our value is proven by the response of the stakeholders: our future clients as magnets distributors and large magnet consuming industries, and e-waste collectors; this is testified by LOIs (from Seval, Garcambiente, Iren, Dismeco, DAB Pumps, MPI srl) and our partnership in the REMHub Consortium. Currently, NdFeB magnets in waste are not recycled because of difficulties in separating magnetic material, this value is lost, so industry is forced to buy new magnets from foreign countries, mainly China. Europe is already dependent on import from magnets, and the demand is increasing: EU NdFeB magnet demand in 2030 will triple compared to 2024, reaching 36,000 tons, with a CAGR forecasted to be 11.3% during the decade. By aligning our prices with the Chinese market price, we reach EBITDA margins of 33% for distributors and 58% for direct clients. In 2030, by reaching a production capacity of 510 ton/year of magnets through plant expansion and a capillary network of dismantling centers in Europe, we will attain a revenue of 33 M€ with a 45% EBITDA margin, satisfying 1.6% of EU NdFeB magnets demand and reaching 2.8% of recycling potential.

REMHub project proposal will create a cutting-edge digital innovation hub propelling EU excellence for Rare Earth Elements (REEs ) and magnets. REMHub will develop test and pilot novel technologies for exploration and primary production of rare earths and recovering rare earths from side streams to enhance supply security of REEs in EU. In addition, Re-X (Recycle, Reuse, refurbishment and repurposing) technologies for rare earths and valuable metals from end-of-life products as well as electric machine design for easier permanent magnet recycling will be developed. The project will also identify and engage relevant stakeholders for developing REE value chain in EU. In addition, in the innovation hub will ensure that the novel technologies developed in the project will be commercialized and offered as services in a digital platform. The project will also have dynamic communication and dissemination with the aim to involve and engage the public to develop trust and awareness related to REEs as well as to build capacity in EU. The hub targets transformative material sourcing for REEs and REE magnets, including traceability, digital twinning, and digital passport. The project partners cover the entire REE value chain starting from mineral exploration, through mineral processing and refining to metal production and magnet making as well as recycling. The project incorporates safe and sustainable by design framework (SSbD) including design for Re-X (recycling, re-use, refurbishment, repurposing) approach integrating easy dismantling and circularity properties. REMHub will significantly improve the supply security of REEs in the EU and with the digital innovation hub considerably accelerate the development of technologies and services to faster and easier market entry.