1. Design Around Rare Earths
- Motors without magnets:
- Induction motors – mature, magnet-free, proven workhorses.
- Reluctance motors – rugged, simple rotors that tolerate heat and vibration well.
- Electrically excited motors – newer designs that achieve magnet-like performance without permanent magnets, now being piloted in electric vehicles and suitable for defense electrification.
- Electronics and radar:
- Development of magnet-less circulators and isolators for radar and EW systems is advancing, reducing dependence on rare-earth crystals and magnets.
- Directed energy & optics:
- Where lasers must use rare-earth dopants, the strategy is to redesign selectively—using alternatives where performance allows, and reducing rare-earth usage where it doesn’t.
2. Build Secure Supply and Recycling
- Domestic/allied supply chains:
- U.S. companies like MP Materials, Lynas USA, and Noveon Magnetics are standing up mining, separation, and magnet production onshore.
- These projects aim to cover the magnets already built into legacy platforms and keep current production flowing.
- Recycling:
- Capturing rare earths from scrap and end-of-life parts allows magnets to be remanufactured.
- This provides a buffer for sustainment while magnet-free technologies mature.
3. Policy and Procurement Guardrails
- Contract rules: New NDAA provisions require disclosure of rare-earth sourcing and will ban magnets from China, Russia, Iran, and North Korea by 2027.
- Program discipline: Each platform should maintain a “rare-earth register” to track where magnets or crystals are used, identify candidates for redesign, and flag where stockpiles or recycled material are needed.
- Dual paths: For every critical assembly, programs should qualify at least one magnet-free option and one non-Chinese supply source.
