Highlights

• Researchers demonstrate a novel method for separating rare earth magnets from electric motors with minimal mechanical damage using controlled debonding techniques.
• The study addresses critical supply chain challenges by enabling potential recycling of up to 2.5 kg of NdFeB magnets per electric motor.
• Proposed recycling strategy could reduce environmental impact and strengthen European supply chain resilience for critical raw materials.

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A new peer-reviewed study led by Dr. Sebastian Veller of the Fraunhofer Institute for Manufacturing Technology and Advanced Materials (opens in a new tab) (IFAM) in Germany highlights a promising pathway to recycle rare earth magnets in electric motors through innovative debonding-on-demand (DoD) strategies. The research, published in Sustainable Materials and Technologies (Elsevier, August 2025), directly addresses one of the most urgent bottlenecks in the rare earth supply chain: the near-total absence of sustainable recycling processes for NdFeB magnets, the critical building blocks of electric vehicles and wind turbines.

Study Findings

The study systematically tested a range of adhesives commonly used in the assembly of permanent magnet synchronous motors (PSMs) and evaluated debonding triggers, including heat (65–400 °C), electric current, and thermally expandable additives. The results show that with appropriate adhesive formulations and controlled external triggers, magnets can be separated from rotors with far less mechanical force, minimal surface damage, and fewer adhesive residues. These advances create the technical basis for automated disassembly lines—turning end-of-life electric motors from scrap metal into a recyclable source of neodymium and dysprosium.

Implications

Global EV sales already exceeded 10 million units in 2022, and forecasts predict rare earth magnet demand could reach 70,000 tonnes annually by 2030. With PSM motors containing up to 2.5 kg of NdFeB magnets each, recycling at scale could significantly reduce supply risks, costs, and environmental impact associated with mining and refining. Fraunhofer’s findings suggest that coupling demagnetization with targeted debonding could enable cost-effective recovery, strengthen European supply chain resilience, and complement policy initiatives such as the EU’s Critical Raw Materials Act.

Limitations

The study underscores several challenges before industrial adoption. Debonding techniques often require high heat inputs or complex electrical contact, raising questions about energy efficiency and scalability. Toxic gas emissions during adhesive pyrolysis necessitate strict safety systems. Moreover, processes remain in a laboratory phase, with industrial automation still in early development. Finally, without regulatory frameworks mandating material recovery or digital product passports, economic incentives for manufacturers remain limited.

Conclusion

Fraunhofer IFAM’s work may represent a crucial step toward a circular rare earth economy. By showing that adhesives in motor assemblies can be engineered for end-of-life debonding, the study provides a roadmap for designing electric motors with recyclability in mind. If scaled, such strategies could transform rare earth magnets from one-time consumables into reusable industrial assets—helping to balance geopolitical supply chains while lowering the environmental footprint of the energy transition.

Citation: S. Veller, M. Adam, M. Hempel, M. Rudlof. Improving the recyclability of rare earth magnets in electrical motors by using debonding strategies. Sustainable Materials and Technologies. Vol. 45, e01586. August 2025. DOI: 10.1016/j.susmat.2025.e01586 (opens in a new tab).

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