Imagine if we could treat old electric car motors like Lego sets, easily popping out the expensive magnets to reuse them. Instead of digging new holes in the ground for rare minerals, this project finds ways to recycle old magnets and mold them into precise shapes with less waste. It's like turning old scrap metal into high-performance engine parts without losing quality.
European EV manufacturers rely on unstable third-country imports for rare earth magnets, facing high costs and environmental footprints. Current recycling is often 'downcycling' and inefficient, leading to significant material waste during manufacturing.
A TRL7 integrated recycling and manufacturing process including Powder Injection Moulding for near-net-shape magnets and a redesigned EVTM rotor for easier dismantling.
If you are an EV motor manufacturer dealing with high raw material costs and supply instability — this project developed a new rotor design and Powder Injection Moulding process that reduces magnet consumption per motor and improves kW/kg performance.
If you are a recycling firm dealing with the difficulty of extracting rare earth elements from scrap — this project developed short-loop recycling and characterization protocols to recover magnets from light and heavy mobility without downcycling.
If you are a magnet producer dealing with high CO2 emissions and material waste — this project developed a process to create high-performance magnets using 25% recycled materials, potentially cutting CO2 emissions by up to 50%.
The future industrialization is estimated to reach a production of up to 2000t/y, which represents 10-12% of the expected European EVTM market in 2040.
It reduces material loss through Powder Injection Moulding (PIM) and utilizes 25% recycled materials in mass, improving the kW/kg of permanent magnets compared to current standards.
Based on available project data, specific licensing terms are not mentioned, but the project demonstrates a disruptive value chain solution at TRL7.
The project runs from January 1, 2024, to March 31, 2027.
The project develops a new EVTM rotor design that improves assembly and facilitates the dismantling of End-of-Life motors for easier recycling.
The consortium is heavily industry-driven with a 56% industry ratio, comprising 9 industrial partners (including 4 SMEs) and 7 research/academic entities across 8 European countries. This strong industrial presence, led by ORANO PROJETS SAS, indicates a high focus on commercial viability and manufacturing scalability rather than pure theoretical research.
Contact ORANO PROJETS SAS regarding the TRL7 pilot line results
Contact us to connect with the MAGELLAN consortium for licensing PIM magnet technology.
