Beijing is now desperately attempting to bring rare earth manufacturing back inside its own borders, exclusively.
New Chinese export restrictions specifically target American plans to begin the country’s first commercial production of rare earth magnet materials by 2027.
To counter that move, REalloys (NASDAQ: ALOY) is rebuilding every major stage of North America’s rare earth industry. Over the past two years, the company has assembled heavy rare earth feedstock, separation, metallization, alloy production, and permanent magnet manufacturing into a single North American mine-to-magnet supply chain designed to operate independently of Chinese material.
And now, the company’s first commercial facilities are expected to come online in the New Year, just as the Pentagon’s ban on Chinese-origin rare earth magnets takes effect, forcing defense manufacturers to secure entirely new sources of supply.
Under the pressure of escalating Chinese export restrictions and the Pentagon’s looming procurement ban, REalloys has become one of the focal points of America’s rare earth rebuild.
The Defense Logistics Agency (DLA) backed the company’s metallization technology, institutional investors committed approximately $100 million to accelerate construction, and the U.S. Army chose REalloys to build the first commercial heavy rare earth processing operation on a U.S. military base.
This is where the front line of the rare earths war shifts from mining to manufacturing.
China’s Step-By-Step Rare Earths War Plan
China’s campaign is advancing one restriction at a time, with each new measure tightening Beijing’s control over the global rare earth industry.
The first step was licensing.
Beijing began requiring exporters to seek approval before shipping key rare earth materials abroad, including the heavy rare earths needed for high-performance magnets. That gave China control over when material leaves the country, who receives it, and how long buyers are forced to wait.
The second step was targeting specific companies.
In June, China added U.S. rare earth firms, including MP Materials and USA Rare Earth, to its export control list, blocking Chinese-origin dual-use materials from reaching them, specifically. That changed the nature of the war entirely.
Now, Beijing was controlling minerals, with the added restriction of also controlling which American companies could ultimately get their hands on them.
The third step was enforcement.
China created a public reporting system for suspected violations involving strategic mineral exports to close any remaining loopholes. Employees, competitors, freight companies, customs brokers, and financial service providers are all now part of the enforcement network. That means that rerouting material through third countries, disguising controlled products, or helping an end user evade restrictions is legally risky.
The fourth step was fear.
Reported detentions of foreign nationals and domestic enforcement actions against Chinese exporters have made suppliers more cautious. A Chinese company that once shipped rare earth material abroad now has to consider customs scrutiny, criminal liability, end-user documentation, and political risk before accepting an order.
The result is a supply chain that is becoming harder for Western companies to use by design. Even when material is technically available, the licensing, paperwork, delays, restricted-party exposure, and enforcement risk make Chinese-origin supply less reliable with every new rule.
Beijing is using rare earth controls to pull more value back inside China. If foreign manufacturers can’t reliably obtain heavy rare earths such as yttrium, dysprosium or terbium, then Chinese manufacturers end up replacing foreign manufacturers as suppliers of finished products.
The American answer to this, and the REalloys solution, is definitive: Recreate the entire supply chain to bypass China, turning the tables on Beijing’s restrictions, which now may prove too late to do as much damage as Beijing was hoping.
The Great American Industrial Buildout
Government support can launch a critical minerals strategy, but it can’t build an industry by itself overnight.
REalloys (NASDAQ: ALOY) reached that milestone in June, raising approximately $100 million from institutional investors to accelerate its vertically integrated mine-to-magnet platform, including what the company says will become the largest heavy rare earth metallization facility outside China and the Western Hemisphere’s first commercial-scale heavy rare earth metallization platform.
The financing provides working capital which is expected to go towards expanding processing, metallization and downstream manufacturing as the company moves toward commercial production, marking the transition from a government-backed concept to an industrial project financed by private markets.
Upstream, midstream, and downstream, REalloys has integrated everything.
Upstream: Non-China Feedstock Secured
REalloys first secured exclusive commercial agreements with the Saskatchewan Research Council (SRC), giving REalloys long-term access to separated heavy rare earth materials, including dysprosium and terbium oxides.
In a rapid succession of offtake deals, REalloys also signed a 15-year definitive offtake agreement with Critical Metals Corp. covering 15% of Phase 1 production from the Tanbreez Project in Greenland, one of the world’s largest rare earth deposits outside China.
Additional agreements with St George Mining in Brazil, Patriot Exploration & Mining in Montana, Ramaco Resources in Wyoming, Kazakhstan-based partners and others expanded the company’s future feedstock pipeline across multiple allied jurisdictions and geological sources.
Those materials are among the hardest to obtain outside China and are essential for the high-temperature permanent magnets used in fighter aircraft, guided missiles, submarines, radar systems and other defense platforms.
Midstream: Battling China’s Metallization Monopoly
For conversion into alloys, also known as “metallization”, REalloys boldly goes where China has dominated for decades. Feedstock is only the first step. Those rare earth oxides must still be converted into high-purity metals before they can be alloyed and manufactured into permanent magnets.
In March, the U.S. Defense Logistics Agency (DLA) awarded REalloys a contract worth up to $1.7 million to design a modular facility capable of producing up to 300 metric tons per year of samarium and gadolinium metals. The award backed REalloys’ metallization technology, recognizing one of the least-developed capabilities in the American rare earth supply chain.
Only days later, REalloys announced plans to build the largest heavy rare earth metallization facility outside China.
The facility is expected to produce approximately 30 tonnes of dysprosium and 15 tonnes of terbium metal annually, converting heavy rare earth oxides into the high-purity metals required for defense-grade permanent magnets. The equipment will be built and commissioned in Saskatoon in partnership with the SRC before being relocated to REalloys’ operations in Euclid, Ohio, where it will supply the company’s downstream alloy and magnet manufacturing platform.
Downstream: The ~$40B Permanent Magnet Industry
As the U.S. Army was negotiating direct rare earths processing for the first time at an American military base, REalloys was not growing complacent. Instead, it was forging its downstream strategy to bring this national security supply chain full circle.
Earlier this month, REalloys signed a strategic agreement with permanent magnet manufacturer JS Link to develop one of the first fully integrated non-Chinese rare earth magnet platforms. The agreement brings together feedstock, separation, metallization, alloy production, and permanent magnet manufacturing under a single North American industrial strategy.
The enormity of this supply chain is exactly why a former Vice Chief of Staff of the Army, the president of GM Defense, a former Chief of Staff to the Secretary of Defense, a former Canadian ambassador to Washington, and one of Wall Street’s senior investment bankers have all converged around REalloys.
The board is chaired by Stephen duMont, the President of GM Defense and a former senior executive at Raytheon Technologies. His career has centered on supplying advanced military systems to the U.S. Department of Defense, giving him direct experience with the procurement processes and industrial requirements that increasingly shape the rare earth industry.
Joining him on the board is General Jack Keane, the former Vice Chief of Staff of the U.S. Army and one of America’s best-known military strategists. Keane has spent decades advising U.S. defense leaders on national security and military modernization, bringing a strategic perspective closely aligned with the Pentagon’s growing focus on securing domestic supplies of critical materials.
The company also appointed Joe Kasper, former Chief of Staff to the U.S. Secretary of Defense, as Chairman of its Advisory Board. Kasper played a central role in defense policy and acquisition during his time at the Pentagon, where rebuilding secure supply chains for strategic materials became an increasingly important national priority.
On the Canadian side, former Canadian Ambassador to the U.S. David MacNaughton and former Saskatchewan Premier Brad Wall provide deep experience in North American industrial cooperation. And on the financial side, REalloys has brought in Bob Foresman, former Vice Chairman of UBS Investment Bank, whose career has focused on international capital markets and large-scale corporate finance.
What they all see is this: A massive opportunity to flip Chinese assumptions that the West will remain dependent on Beijing for its defense.
REalloys' strategy also reflects a much broader shift taking place across the North American industrial base. MP Materials (NYSE: MP) is expanding beyond mining into domestic magnet production, while global mining heavyweight Rio Tinto (NYSE: RIO) continues increasing its exposure to critical minerals as demand for rare earths, lithium and other strategic materials accelerates. The industry is increasingly moving away from simply extracting raw materials toward securing entire supply chains, from mining and processing to advanced manufacturing.
That transition matters because some of America's largest industrial companies depend on secure access to these materials. Honeywell (NASDAQ: HON) uses rare earth-based technologies across its aerospace, automation and defense businesses, while Caterpillar (NYSE: CAT) is incorporating greater electrification, autonomous systems and advanced motors into its mining and construction equipment. As China's export controls become more restrictive, companies throughout the manufacturing sector are recognizing that supply chain security has become just as strategically important as access to the minerals themselves.
Rather than viewing rare earths as simply another mining story, investors are increasingly seeing them as the foundation of the next generation of American industrial manufacturing. The companies that can secure reliable supplies of critical minerals, processing capacity and permanent magnets will be better positioned to support the growing needs of defense, aerospace, electric vehicles, robotics and AI-driven infrastructure in the years ahead.
With commercial production approaching, private capital complementing government seed funding, and defense procurement rules about to change permanently, this Rare Earths War is moving from policy papers to factory floors. For the first time in a generation, the United States is approaching the point where it can compete for the entire rare earth value chain instead of simply buying pieces of it from abroad.
By. Michael Kern
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