PASSENGER addresses to the topic CE-SC5-10-2020 on raw materials innovation under subtopic d) Pilots on substitution of critical and scarce raw materials (2020). PASSENGER aims to develop innovative pilots to address an aspect of high economical, technological, social and environmental relevance: a solution for the EU dependency on rare-earths (REs) for permanent magnets (PMs), avoiding bottlenecks in the material supply-chain and diminishing the environmental impact. Considering the importance of PMs in present and emerging technologies, PASSENGER will develop up scaled alternatives based on widely available resources and innovative technologies. PASSENGER has a clear industrial orientation involving key end users and SMEs/LEs (13 industrial partners) from 8 EU countries. PASSENGER will develop a sustainable substitution pilot in PMs subdivided in 8 innovative pilot activities covering the complete value chain to finish at TRL7 and to guarantee implementation across the EU after the project is finished. The choice of PMs is based on realistic (envisioned up-scaling, low cost and environmental impact) projects results and patents (proven at TRL 4-5) achieved by the partners in successful EU projects: Improved Strontium ferrite (Sr-ferrite), Manganese-Aluminum-Carbon (MnAlC) and related technologies. These RE-free PM alternatives will substitute bonded NdDyFeB-magnets, which are constituted by diverse critical raw materials: REs (Nd and Dy, and Pr in some compositions); Metal (Cobalt). Electromobility has been chosen as a main key-driving sector with three application areas: Class 1: e-scooter; Class 2: e-bikes and e-motorbikes; Class 3: e-cars. The project will be done under premises of sustainability and reduced environmental impact, including Standardisation activities, Life Cycle Assessment (LCA) and Life Cycle Cost (LCC) analysis, recyclability and social-life cycle assessment of PASSENGER’s products and technologies.

PERMANET is a Sustainable REE Innovation and Supply Network covering the full Rare Earth Elements (REE) Permanent Magnet (PM) value chain. It is structured upon 5 layers: 1) Three Sustainable, Connected Tech ‘Hubs’ segmented along the full REE PM value chain and organizing thematic collaborative R&D and supply ecosystems 2) 13 fully Scalable Innovations to reach TRL7 and expand in scale and deployment range along the entire value chain 3) A structural layer of R&D infrastructure, equipment and services to fuel Pilot and Demonstration activities 4) Five Enabling “Engines” addressing the key conditions for sustainable and competitive REE supply 5) All embedded within a single PERMANET Network Infrastructure with its own, sustainable organizational model. The Network accelerates leading-edge innovations, from REE extraction from mining tailings and hydrometallurgical processes to oxide reduction and innovative production processes, all the way to the production of innovative PM and their testing by end users in industrial environment across 1/ E-Mobility 2/ Energy 3/ Industrial Equipment. PERMANET also secures key sources of REE such as leading mining projects from the EU and Partner Countries, as well as End of Life (EoL) sectors (WEEE, EV, etc.). The project relies on enabling activities ranging from strategic venturing to investment support to build sub-optimal EU REE PM Segments. The project unlocks viable reserves of REE including unconventional sources and will demonstrate novel, cost-effective, and environmentally sound REE extraction, processing, and separation routes, as well as demonstrate the first EU hub for PM boosting circular PM technologies to deploy at market scale. The project is ready to be fully integrated with other EU-backed PM Hubs and aims to grow into a fully-fledged Pan-EU pilot and demonstration infrastructure to remain sustainable post-funding.

AddMag is an ambitious project resolutely turned towards the future, new processing technologies, low carbon energy applications and the circular economy. The project proposes the additive manufacturing of two permanent magnet materials: Nd-Fe-B and Fe-Cr-Co. The overall ambitions of this project are in line with those of the Europe Union and the respective funding organisations and namely: • Enabling European independence on magnet materials • Developing novel processes that will enable relocating magnet production within Europe • Acting towards more flexibility and cost reduction in the fabrication of magnets by additive manufacturing • Proposing the use of novel recycling methods to capitalise on the EU urban mine • Proposing environmentally friendly and resource efficient production processes for magnets By implementing those global ambitions in a technical and scientific project, the first aim is to establish Laser Beam – Powder Bed Fusion (LPBF) and material extrusion (MEX) as novel and reliable methods in the production of permanent magnet materials. For that purpose, wide range of printing parameters resulting in different production conditions (including anisotropic printing and in-situ alloying) will be used at the Institute of Materials Science, Joining and Forming TU Graz (IMAT) and Jozef- Stefan Institute (JSI) to influence the magnet properties. Dilatometry at the Institute for Materials Physics, TU Graz (IMP) will evaluate the effect of different printing conditions on the anisotropy in the microstructure which is crucial for the development of the magnetic properties of the printed magnets. Microstructure studies as well as characterisation of the magnet properties will be carried out at Néel Institute, Grenoble, France (NEEL). Additionally, post printing treatments will be assessed at NEEL too to further optimise the magnet properties by developing anisotropy in Fe-Cr-Co through thermomagnetic treatments or by improving coercivity in Nd-Fe-B magnets through dedicated annealing. Nd-Fe-B is the most widely used hard magnetic material in applications including the electronic and automotive sectors, electromobility and wind powder (e.g. motors, turbines, magnetic valves, sensors). Neodymium, which is a rare earth metal and on the EU list of critical elements, is required in the production of this material. Therefore, one incentive in the European Union is to develop processes for the efficient use and re-use of this resource. In this project, end-of-life Nd-Fe-B magnets will be recycled and manufactured into a powder suitable for the laser beam – powder bed fusion process by MagREEsource. This powder, once optimised, will serve as a basis for direct low temperature printing of Nd-Fe-B parts or as starting materials in the production of amorphous Nd-Fe-B powder by Metalpine suitable for breakthrough LPBF printing processes. Fe-Cr-Co is a medium hard magnetic material, which is handled as a possible alternative to rare earth magnets, especially in areas, where those materials are not explicitly required (e.g. large electric engines). Another advantage of Fe-Cr-Co in comparison to similar materials of the same material class (e.g. Al-Ni-Co) is its low cobalt content. A higher market share of this material at the expense of higher Cobalt containing materials would have positive effects on the environment and local societies in the future, since the mining of Cobalt is environmentally and ethically problematic. Finally, the magnet printed parts will be tested for a potential future use in different applications, such as: Nd-Fe-B based magnetic sensors and valves in the automotive field (AVL) and lifting systems using Fe-Cr-Co (Vegatechnik, VEG). The ability to produce complex shaped magnets provides manufacturers of electric devices with greater freedom in design and construction while simultaneously developing enhanced anisotropic magnet properties.