New Processing Technology for Permanent Magnets

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OPEN 2012
Landisville, Pennsylvania
Project Term:
04/15/2013 - 02/14/2017

Technology Description:

Electron Energy Corporation (EEC) and its team are developing a new processing technology that could transform how permanent magnets found in today’s EV motors and renewable power generators are fabricated. This new process, known as friction consolidation extrusion (FC&E), could produce stronger magnets at a lower cost and with reduced rare earth mineral content. The advantage of FC&E over today’s best fabrication processes is that it can be applied to unconsolidated powders as opposed to solid alloys, which can allow magnets to be compacted from much smaller grains of two different types, a process which could double its magnetic energy density. EEC’s process could reduce the need for rare earth mineral in permanent magnets by as much 30%.

Potential Impact:

If successful, EEC’s new process would support the growing market of renewable power generators and EV motors with alternative higher-performance magnets compared to the imported rare earth magnets currently used in these machines.


The U.S. produces a small fraction, globally, of industrial rare earths. Developing alternatives to the use of rare earths has the potential to reduce our dependence on these materials and will have a positive impact on our national economic and energy security.


The transportation and electric power sectors account for nearly 75% of U.S. greenhouse gas emissions each year. Cheaper motors will encourage the widespread use of EVs and wind power, significantly reducing emissions.


The U.S. spends nearly $1 billion per day on imported petroleum. Improvements in motor technology will encourage broader use of EVs, reducing the economic impacts of oil price fluctuations.


ARPA-E Program Director:
Dr. Ji-Cheng Zhao
Project Contact:
Dr. Jinfang Liu
Press and General Inquiries Email:
Project Contact Email:


Pacific Northwest National Laboratory
Ames National Laboratory

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