Roughly 40 years ago, the United States made a decision that seemed perfectly rational at the time: it stopped processing rare earths.

The economics didn’t make sense when China could do it cheaper, so U.S. facilities closed…the expertise scattered…and an entire layer of industrial capability mostly disappeared from North American soil.

REalloys (Nasdaq: ALOY) is the company now working to undo the four decades of neglect that have followed…and the reason it matters is that the expertise it holds may be the single hardest thing in the rare earth supply chain to replace.

In fact, the Center for Strategic and International Studies has identified rare earth metallization and alloying as the least developed and most difficult capability to rebuild outside China. According to CSIS, this kind of expertise is learned over long operating histories, not built on a schedule. It’s the kind of expertise that can only be built through years of doing it…and no amount of money can speed that up.

So if it takes decades to build this expertise, and America gave it away 40 years ago, where does that leave us?

The answer is both alarming and surprisingly specific. It leaves us with a facility in Euclid, Ohio, that never let the knowledge die.

How America Lost Control of a Critical Industrial Capability

The West didn’t lose its rare earth processing capability to espionage or theft. It lost it to economics.

Starting in the 1980s and accelerating through the 1990s, China made a deliberate decision to invest heavily in rare earth mining and processing. State support absorbed losses, environmental controls were minimal, and labor was cheap. The result was a production cost that no Western facility could match. One by one, processing operations across North America and Europe shut down. The last major U.S. rare earth mine, Mountain Pass in California, closed in 2002.

But what disappeared was far more than a few facilities. The people who knew how to run them retired or moved on, and the specialized equipment was decommissioned. The institutional knowledge of how to separate 17 individual rare earth elements, how to convert oxides into metals at extreme temperatures, and how to alloy those metals to exact specifications for defense and industrial use…well, that accumulated expertise simply ceased to exist in the West.

As one rare earth processing expert put it bluntly: the West abdicated its rare earth processing capability to China. The skillsets, the workforce, the equipment, and the process knowledge are now 30 years behind, and none of it can be developed overnight.

China understood the value of what it was accumulating. While Western companies optimized for short-term profitability, China was playing a longer game, building deep process knowledge, training specialized workforces, and integrating downstream into metals, alloys, magnets, and finished components. By the time anyone in the West noticed how dependent they’d become, China controlled approximately 90–95% of global rare earth processing and an even larger share of finished magnet production.

Companies across the Western critical minerals sector are now racing to rebuild pieces of the supply chain that disappeared decades ago. NioCorp Developments (NASDAQ: NB) is advancing the Elk Creek project in Nebraska to supply strategic minerals and rare earths for defense and advanced manufacturing applications, while Critical Metals Corp. (NASDAQ: CRML) is developing critical mineral assets tied to Western supply chain security efforts. Meanwhile, Idaho Strategic Resources (NYSE American: IDR) has expanded its focus on strategic and rare earth-related mineral development as geopolitical concerns push governments to secure domestic resource capacity. Together, these companies reflect a growing realization across the West: rebuilding rare earth and critical mineral security requires far more than mining alone — it demands an integrated industrial chain capable of processing, refining, and manufacturing strategic materials outside China.

No Amount of Money Can Replace 40 Years of Knowledge

In most industries, a big enough check can close a competitive gap pretty quickly. You build the factory, hire the right people, buy the equipment, and scale up. In rare earth processing, that simply doesn’t work.

Converting rare earth minerals into defense-grade metals and alloys is an extraordinarily complex industrial process. It involves separating 17 individual rare earth elements through multi-stage solvent extraction…then converting purified oxides into metals at temperatures exceeding 1,200 degrees…then precision alloying to exact specifications across thousands of individual micro-steps…and all of this must be controlled with extreme precision.

Each stage requires specialized knowledge that can only be built through years of hands-on operation. There are no textbooks that teach it. There are no consultants who can install it. It has to be learned by doing, failing, adjusting, and doing it again over years and years.

The SRC facility in Saskatchewan, built by REalloys’ processing partner, illustrates just how steep the learning curve is. When China blocked the export of processing technology in 2020, SRC had to design and build its own systems from scratch.

It took years of work by a multidisciplinary team of mineral experts, processing specialists, and AI engineers working in concert. The AI system alone was trained by deliberately breaking the separation process over and over for months until it ran out of problems to solve….

Even with SRC’s 15 years of prior experience working with rare earth clients, it still took years to get to where they are today, which is producing higher-purity metals with six people and an AI system, compared to the 80 workers a comparable Chinese facility would require.

Now think about what a competitor starting from zero would be up against. They’d have no operating history, no accumulated process data, no trained workforce, and no AI dataset built from years of real-world production. They’d essentially be starting from a blank page. Industry estimates put the realistic timeline at three to seven years for a credible challenger, and that assumes everything goes right. Some experts say longer.

The Company That Kept the Expertise Alive

This is what makes REalloys’ position so unusual in the rare earth space. While almost every other Western company is trying to build processing capability from scratch, REalloys acquired something that already existed: four decades of accumulated expertise.

Through its acquisition of PMT Critical Metals, REalloys (Nasdaq: ALOY) took ownership of the Euclid, Ohio, facility along with more than 30 years of applied development in specialty metals processing. That includes eight years of focused work on rare earth metallization in collaboration with U.S. national laboratories and the Defense Logistics Agency, which is work that involved thousands of production runs, failed experiments, and iterative redesigns carried out in operating facilities rather than academic labs.

The Euclid facility is currently the only site in North America with a proven track record of delivering rare earth metals and alloys to government and commercial partners.

It already holds contracts with the U.S. Department of Defense, Department of Energy, and NASA. And the processes it uses have been demonstrated, tested, and qualified under real-world conditions, which is what separates operational expertise from a business plan.

Andrew Sherman, REalloys’ Head of Research and Development, describes the Euclid facility as a platform the company can build from rather than something it has to invent. The remaining work, he says, is about expanding capacity and locking in long-duration defense programs where material supply is committed for years. The hardest part, which is proving the process works, has already been done.

That distinction is critical. Defense and industrial customers qualify processes and the people and facilities behind them, not technologies on paper. Qualification can take several years, and once a supplier is locked in, switching becomes a technical and regulatory undertaking that nobody takes on willingly. A company starting from scratch today would need to build the expertise, prove the process, and then spend years getting qualified…all while REalloys is already delivering.

Expertise Backed by a Complete Supply Chain

But the Euclid facility’s expertise doesn’t operate in isolation. It anchors a broader supply chain that REalloys has built to take raw material all the way to finished magnets, all within North America. And all of it is designed to operate without any critical reliance on Chinese technology, equipment, or consumables.

Upstream, the company owns the Hoidas Lake rare earth project in Saskatchewan and has secured feedstock agreements with partners in Kazakhstan, Brazil, and Greenland. Midstream, it holds an exclusive 80% offtake on production from the Saskatchewan Research Council’s Rare Earth Processing Facility in Saskatoon, targeting first commercial production in late 2026 to early 2027. Downstream, the Euclid facility will handle the metallization, alloying, and magnet manufacturing that defense and industrial customers actually need.

By early 2027, the combined platform is expected to produce approximately 525 tonnes per year of neodymium-praseodymium metal, roughly 30 tonnes of dysprosium oxide, and 10 tonnes of terbium oxide. At that scale, the SRC facility would be the largest source of heavy rare earth oxides outside China, sitting right in North America’s backyard.

Phase 2 plans call for significantly larger production later this decade, including approximately 200 tonnes per year of dysprosium metal, 45 tonnes of terbium metal, with capacity to produce up to 20,000 tonnes per year of heavy rare earth permanent magnets.

That timing is critically important, as on January 1, 2027, updated U.S. defense procurement rules under DFARS take effect that will restrict the use of Chinese-origin rare earth materials in qualifying weapons systems. That creates immediate, government-mandated demand for domestically processed, defense-compliant material, which is exactly what REalloys’ Euclid facility has spent 40 years learning to produce.

The institutional support behind REalloys reflects the seriousness of the undertaking. The U.S. Export-Import Bank has issued a $200 million letter of intent to support the company’s supply chain development.

And the company’s board includes Chairman Stephen S. DuMont, President of GM Defense; General Jack Keane (Ret.), four-star general and recipient of the Presidential Medal of Freedom; former Saskatchewan Premier Brad Wall; and former Canadian Ambassador to the U.S. David MacNaughton.

The Head Start That Money Can’t Erase

The rare earth conversation in America has been dominated for years by mining companies, resource estimates, and announcements about billions of dollars in new investment.

But the real constraint was never about how much rock you could pull out of the ground or how much money you could throw at the problem. It was always about expertise…the deep, accumulated, experience-driven knowledge of how to turn raw material into something a defense contractor or manufacturer can actually use.

The West gave that expertise away 40 years ago. Most of it is gone for good. Rebuilding it from scratch will take years at a minimum, and the CSIS assessment makes clear that this timeline cannot be shortened with capital alone.

REalloys didn’t have to rebuild from scratch. Through its Euclid facility, it inherited three decades of operational expertise that has been continuously maintained, developed, and proven through real-world production and government contracts. That’s the kind of asset that no competitor can replicate simply by raising more money because the knowledge inside that building wasn’t built with money. It was built with time.

In a market where everyone else is racing to build what REalloys already has, that 40-year head start may be the most valuable asset in the entire rare earth space. And with the 2027 defense procurement deadline approaching fast, the value of that head start is about to become very difficult to ignore.

By. Josh Owens

The AI boom is triggering an unexpected and unprecedented bull run in natural gas and power stocks. If you aren’t paying attention to the energy demands of data centers, you will miss the biggest energy story of the decade. The smart money is already quietly moving into the few companies prepared to power the trillion-dollar AI machine.

Oilprice Intelligence brings you the inside view on where the next gains will come from, breaking down the market’s biggest growth driver with analysis from veteran oilmen and experts. Click here to get this crucial intel for free

IMPORTANT NOTICE AND DISCLAIMER

FORWARD LOOKING STATEMENTS
This publication contains forward-looking statements, including statements regarding expected continual growth of the featured companies and/or industry. The Publisher notes that statements contained herein that look forward in time, which include everything other than historical information, involve risks and uncertainties that may affect the companies’ actual results of operations. Factors that could cause actual results to differ include, but are not limited to, changing governmental laws and policies concerning, among other things, recreational and medical cannabis sales, success of the company’s proprietary technology, the size and growth of the market for the company’s products and services, the company’s ability to fund its capital requirements in the near term and long term, pricing pressures, etc. 

SHARE OWNERSHIP
Neither the author nor the publisher, Oilprice.com, was paid to publish this communication concerning REalloys (NASDAQ: ALOY). However, the owner of Oilprice.com owns shares and/or stock options of the featured company and therefore has an incentive to see the featured company’s stock perform well. The owner of Oilprice.com may buy or sell shares of the featured company at any time including at or near the time you receive this communication. This share ownership should be viewed as a major conflict with our ability to be unbiased. This is why we stress that you conduct extensive due diligence as well as seek the advice of your financial advisor or a registered broker-dealer before investing in any securities.

This communication is not, and should not be construed to be, an offer to sell or a solicitation of an offer to buy any security. Neither this communication nor the Publisher purport to provide a complete analysis of any company or its financial position. The Publisher is not, and does not purport to be, a broker-dealer or registered investment adviser. This communication is not, and should not be construed to be, personalized investment advice directed to or appropriate for any particular investor. Any investment should be made only after consulting a professional investment advisor and only after reviewing the financial statements and other pertinent corporate information about the company. Further, readers are advised to read and carefully consider the Risk Factors identified and discussed in the advertised company’s SEC, SEDAR and/or other government filings. Investing in securities is speculative and carries a high degree of risk. Past performance does not guarantee future results. This communication is based on information generally available to the public and does not contain any material, non-public information. The information on which it is based is believed to be reliable. Nevertheless, the Publisher cannot guarantee the accuracy or completeness of the information.

INDEMNIFICATION/RELEASE OF LIABILITY
By reading this communication, you acknowledge that you have read and understand this disclaimer, and further that to the greatest extent permitted under law, you release the Publisher, its affiliates, assigns and successors from any and all liability, damages, and injury from this communication. You further warrant that you are solely responsible for any financial outcome that may come from your investment decisions.

TERMS OF USE
By reading this communication you agree that you have reviewed and fully agree to the Terms of Use found here http://oilprice.com/terms-and-conditions If you do not agree to the Terms of Use http://oilprice.com/terms-and-conditions, please contact Oilprice.com to discontinue receiving future communications.

INTELLECTUAL PROPERTY
Oilprice.com is the Publisher’s trademark. All other trademarks used in this communication are the property of their respective trademark holders.  The Publisher is not affiliated, connected, or associated with, and is not sponsored, approved, or originated by, the trademark holders unless otherwise stated. No claim is made by the Publisher to any rights in any third-party trademarks.