Summary: A new pre-feasibility study outlines three additional U.S. NdFeB recycling and magnet plants plus a centralized finishing hub, alongside HyProMag USA’s planned Northlake facility. The study defines a possible four-plant platform, but financing, permits, construction, feedstock, and customer qualification remain future work.
The study moves expansion from concept to pre-feasibility
HyProMag USA announced completion of an independent pre-feasibility study by PegasusTSI and BBA USA for three proposed regional plants in South Carolina, Nevada, and a second Texas location. These would operate alongside the Northlake, Texas facility that is already in detailed engineering.
The proposed plants would use Hydrogen Processing of Magnet Scrap technology to recover material from end-of-life magnets. The study also evaluated a second case that adds primary NdFeB alloy feedstock, giving the platform flexibility when recycled material alone is insufficient or commercially unattractive.
A central hub would handle high-value finishing
Under the study configuration, regional plants would produce unfinished sintered NdFeB blocks. A Central Texas Hub would then provide alloy processing, grain-boundary diffusion, machining, plating, passivation, epoxy coating, quality assurance, and customer qualification.
This separation of regional recovery from centralized finishing addresses an important commercial bottleneck. Producing a magnet block is not the same as supplying a qualified component. Buyers also require dimensional control, surface protection, magnetic-property verification, traceability, and application-specific validation.
Capacity and financial figures remain forecasts
Together with Northlake, the platform targets about 4,192 metric tons per year of saleable NdFeB magnets by 2034, plus alloy powder and other saleable material. The pre-feasibility study estimated capital of approximately $623 million for the recycled-feedstock-only case and $656 million for the combined recycled-and-primary-feedstock case covering the three new plants.
The company also published projected net present value, internal rate of return, costs, selling prices, and payback periods. These figures depend on forecast magnet prices, construction schedules, capital estimates, operating assumptions, feedstock availability, and other inputs. They are study outputs, not guaranteed project returns or operating results.
What magnet buyers should verify
- Which magnet grades and geometries will be available at each commissioning stage.
- How recycled and primary feedstocks will be segregated, blended, and traced.
- Customer qualification timing for coating, corrosion, temperature, and magnetic performance.
- Firm feedstock contracts, offtake commitments, permits, financing, and equipment orders.
- Whether the centralized finishing model creates transport or schedule bottlenecks.
The Northlake Phase 1 facility is still targeted for commissioning in mid-2028, while the three expansion plants are planned in later stages. The pre-feasibility study strengthens the engineering framework for a U.S. recycling-to-magnet platform, but it should not be described as completed capacity or confirmed supply.
Source: HyProMag USA release distributed by ACCESS Newswire, October 26, 2026.