Energy Fuels Achieves U.S. Breakthrough in Heavy Rare Earth Production

In a landmark development for American manufacturing, Energy Fuels Inc. announced on March 24, 2026, the successful production of high-purity terbium oxide-the first such primary output in the United States in decades. Sourced entirely from domestic monazite ore, this heavy rare earth element (REE) achieved 99.9% purity at pilot scale, meeting the exacting standards required by global manufacturers of rare earth permanent magnets (REPMs). Terbium plays a pivotal role in enhancing the thermal stability and magnetic strength of these magnets, which are indispensable in aerospace applications from jet engine actuators to satellite guidance systems.

The aerospace industry stands to benefit immensely from this advancement. Modern fighter jets, commercial airliners, and unmanned aerial vehicles rely on samarium-cobalt and neodymium-iron-boron magnets doped with terbium to withstand extreme temperatures exceeding 300°C and intense vibrational stresses during flight. Without it, critical components like avionics, navigation gyros, and thrust vector controls could fail under operational duress, compromising safety and mission reliability. Energy Fuels' CEO Mark Chalmers emphasized that this capability positions North America to secure a reliable supply for defense technologies and high-performance aviation hardware.

This follows the company's recent production of nearly 30 kg of 99.9% pure dysprosium oxide, another heavy REE essential for similar magnet applications. Dysprosium complements terbium by boosting coercivity-resistance to demagnetization-ensuring actuators in aircraft engines maintain precision even in high-heat environments. Together, these elements address a glaring vulnerability: over 90% of global heavy REE processing has historically been controlled by China, creating supply chain risks amplified by geopolitical tensions and export restrictions.

The implications extend to satellites and navigation systems, where lightweight, durable REPMs enable precise attitude control and long-duration missions in harsh orbital conditions. For instance, terbium-enhanced magnets power reaction wheels that keep satellites oriented for communication and Earth observation, directly impacting reliability in space-based defense networks. Energy Fuels' scalable process not only mitigates these risks but also proves economic viability, paving the way for commercial production at their White Mesa Mill in Utah.

As U.S. policy tightens domestic sourcing mandates for defense contractors by 2027, this breakthrough accelerates the reshoring of critical materials. It underscores a strategic pivot toward self-sufficiency, ensuring aerospace innovators like Lockheed Martin and Boeing can meet performance demands without foreign dependencies. With further expansions planned, Energy Fuels is poised to supply the magnets that keep aircraft soaring and satellites locked on target.