Ames, Iowa, September 13, 2025
News Summary
Ames National Laboratory’s Critical Materials Innovation Hub has licensed a cutting-edge rare earth metals processing technology to Principal Mineral, aimed at accelerating the domestic production of neodymium and Nd-Fe-B magnets. The innovative REMAFS process utilizes metallothermic reduction without harmful acids, significantly enhancing safety and environmental impact while streamlining processing steps. This partnership signifies a public-private collaboration focused on securing critical mineral supplies in the U.S. and reducing dependency on foreign sources.
Ames, Iowa
Ames National Laboratory’s Critical Materials Innovation (CMI) Hub has licensed a new rare earth metals processing technology to Principal Mineral of Dallas, Texas. The technology is built on the Rare Earth Metals via Alternative Fluoride Salt (REMAFS) process, which uses metallothermic reduction without generating or using harmful acids. The license is expected to accelerate domestic production of neodymium metal and Nd-Fe-B magnets while improving safety, environmental impacts, and scalability.
Key details
The REMAFS-based technology can be integrated earlier in the rare earth supply chain, reducing the number of processing steps required to convert mined materials into usable rare earth metals. CMI research led by the project lead responsible for REMAFS indicates that magnets produced from REMAFS-derived metals are of equivalent quality to magnets made with commercially available rare earth metals. Principal Mineral has obtained the license to commercialize and scale the process in the United States.
Technical and commercial implications
The REMAFS process relies on metallothermic reduction to extract rare earth metals, a method noted for avoiding use of strong acids that are common in traditional routes. This approach reduces hazardous waste generation and can simplify plant permitting and waste management. By enabling integration earlier in the supply chain, the process removes several intermediate conversion steps, which can lower costs, shorten lead times, and reduce cumulative environmental impacts across the production chain.
Research outcomes associated with the REMAFS pathway demonstrate that resulting metals are suitable for producing high-performance Nd-Fe-B magnets, a critical component in electric motors, wind turbines, and other clean energy technologies. The combination of performance equivalence and reduced environmental footprint supports wider domestic adoption for strategic supply chain resilience.
Partnership and strategic context
The licensing arrangement between Ames National Laboratory’s CMI Hub and Principal Mineral is intended as a public-private partnership to translate laboratory innovation into commercial capacity. The collaboration aligns with broader U.S. strategic priorities focused on securing domestic supplies of critical minerals and reducing dependence on foreign sources for essential materials used in defense and clean energy applications.
Principal Mineral, a company that develops and scales domestic production of strategic metals, high-performance alloys, and advanced materials through mining, processing, and recycling, will pursue commercialization and scale-up activities. The agreement is positioned as part of industry efforts to expand secure, reliable, and more environmentally sustainable domestic manufacturing for rare earth materials.
Institutional and program information
The Critical Materials Innovation (CMI) Hub is an Energy Innovation Hub led by Ames National Laboratory with support from the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy, specifically the Advanced Materials and Manufacturing Technologies Office (AMMTO). Ames National Laboratory is operated by Iowa State University and has produced scientific breakthroughs for more than 75 years, tracing institutional roots to work on the Manhattan Project.
CMI’s outputs over the past 12 years include more than 730 technical publications, six open-source software packages, licensing of 25 technologies, and 65 awarded U.S. patents. The laboratory operates with an approximate annual budget of $60 million and employs more than 470 staff. CMI previously hosted a webinar titled “Navigating Volatility in Critical Mineral Markets,” which remains available on the CMI YouTube channel for stakeholders seeking background on market dynamics and technology deployment.
Contacts and next steps
For information on partnerships or licensing of CMI technologies, the designated point of contact is Stacy Joiner. Principal Mineral intends to move forward with commercialization and scaling activities for the REMAFS-based process, with implementation timelines to depend on demonstration, permitting, capital deployment, and market demand for rare earth metals and magnets.
Impacts and outlook
Adoption of the REMAFS process could influence several aspects of the domestic rare earth ecosystem: reducing hazardous chemical use, simplifying processing sequences, enabling faster ramp-up of domestic metal and magnet production, and supporting federal and industry efforts to strengthen supply chain resilience. Continued evaluation during scale-up will determine long-term environmental and economic performance relative to incumbent routes.
FAQ
What is the REMAFS process?
REMAFS stands for Rare Earth Metals via Alternative Fluoride Salt. It is a metallothermic reduction process that extracts rare earth metals without using or producing strong acids, lowering hazardous waste and permitting complexity compared with some traditional methods.
Who holds the license for the technology?
Principal Mineral of Dallas, Texas, has been licensed to commercialize and scale the REMAFS-based rare earth metals processing technology developed by the CMI Hub at Ames National Laboratory.
Will REMAFS produce magnets that meet current performance standards?
Research led by the CMI project team indicates magnets produced from REMAFS-derived metals match the quality of magnets made from commercially available rare earth metals, including Nd-Fe-B magnets used in many clean energy applications.
How does this affect the supply chain?
REMAFS can be integrated earlier in the supply chain, reducing the number of conversion steps required and potentially lowering costs, lead times, and environmental impacts while supporting domestic production capacity.
Who manages CMI and how can organizations engage?
CMI is led by Ames National Laboratory with support from the DOE Office of Energy Efficiency and Renewable Energy’s AMMTO. Organizations interested in partnerships or licensing are advised to contact Stacy Joiner at CMI.
Key features and expected benefits
| Feature | Description | Expected Benefit |
|---|---|---|
| REMAFS process | Metallothermic reduction using alternative fluoride salt chemistry | Reduces acid use and hazardous waste |
| Supply chain integration | Can be applied earlier in mineral-to-metal conversion | Fewer processing steps; lower cost and faster timelines |
| Magnet quality | Produces metals suitable for Nd-Fe-B magnet manufacture | Meets performance needs for motors and clean energy devices |
| Scalability and safety | Process designed for reduced hazardous inputs and scalable operation | Improved permitting prospects and industrial throughput |
Deeper Dive: News & Info About This Topic
HERE Resources
Additional Resources
- Newswise: CMI Technology for Rare Earth Processing
- Wikipedia: Rare Earth Elements
- Iowa Capital Dispatch: Ames National Laboratory Names New Director
- Google Search: Rare Earth Processing
- WFFT: Latta: Ames Lab Pivotal in U.S. Energy Innovation Efforts
- Encyclopedia Britannica: Energy
- Business Record: Karl Mueller Named Director of Energy Department’s Ames National Laboratory
- Google Scholar: Critical Materials Innovation
- Canary Media: Iowa Company Recycles Rare Earth Materials
- Google News: Ames National Laboratory
Author: STAFF HERE DALLAS WRITER
DALLAS STAFF WRITER The DALLAS STAFF WRITER represents the experienced team at HEREDallas.com, your go-to source for actionable local news and information in Dallas, Dallas County, and beyond. Specializing in "news you can use," we cover essential topics like product reviews for personal and business needs, local business directories, politics, real estate trends, neighborhood insights, and state news affecting the area—with deep expertise drawn from years of dedicated reporting and strong community input, including local press releases and business updates. We deliver top reporting on high-value events such as the State Fair of Texas, Deep Ellum Arts Festival, and Dallas International Film Festival. Our coverage extends to key organizations like the Dallas Regional Chamber and United Way of Metropolitan Dallas, plus leading businesses in telecommunications, aviation, and semiconductors that power the local economy such as AT&T, Southwest Airlines, and Texas Instruments. As part of the broader HERE network, including HEREAustinTX.com, HERECollegeStation.com, HEREHouston.com, and HERESanAntonio.com, we provide comprehensive, credible insights into Texas's dynamic landscape.
