In 1992, China’s political leader Deng Xiaoping made a comparison that should’ve set off alarms across the West: “There is oil in the Middle East; there is rare earth in China.”
Instead, for the next 30 years, Western governments largely treated rare earth processing as low-value work — something they could hand off to whoever would do it cheapest. But then REalloys (NASDAQ: ALOY) came along with partners and started building domestic processing capability while most of the industry was still looking the other way.
Beijing saw the value in rare earths early and treated it as a long-term weapon, which is why China now controls roughly 90% of global rare earth processing
That covers not just mining, but the refining and metal-making that turn raw rock into parts for everything from fighter jets to wind turbines.
It spent 30 years building that position deliberately, with state-backed financing, predatory pricing, and export controls designed to prevent anyone else from catching up.
And the approach has paid off. When Beijing threatened to cut off processed rare earths during tariff talks last year, the Trump administration reversed course within days. It’s no surprise, given that China controls the supply of materials our military can’t function without.
While the rare earth shortage has started making headlines over the last year or so, REalloys saw this coming years ago. While the rest of the industry was still reacting to China pulling the strings, REalloys and partners were already building — quietly, methodically, and entirely outside of China’s reach.
Now in March, the company announced it’s fully financed to build the largest heavy rare earth metallization facility outside China, after its recently completed $50 million public offering.
The roughly $40 million facility will produce about 30 tonnes of dysprosium and 15 tonnes of terbium metal per year. These are the heavy rare earths that keep magnets working inside jet engines, missile guidance systems, and advanced drone platforms where failure is not an option.
But to understand why this is so critical in today’s rare earth shortage, you have to understand how Beijing set the trap years ago.
How China Built the Most Effective Trade Weapon on Earth
China did not simply stumble into its monopoly on rare earth processing. It was a three-decade strategy, executed with patience and precision while the West gave away its processing capabilities and barely looked back.
A bipartisan Congressional probe released in November 2025 laid out the playbook in detail.
Beijing hands “tens of billions of dollars, including zero-interest-rate loans” to state mining firms. It built a legal framework for controlling mineral prices. And whenever the West started to invest, China flooded global markets to crush it.
Committee Chairman John Moolenaar put it bluntly: “From cell phones to fighter jets, every American is dependent on minerals that China manipulates for its own selfish interests. As we saw last month with its rule on rare earths, China has a loaded gun that is pointed at our economy, and we must act quickly.”
The consequences have already shown up on factory floors. When Beijing tightened export approvals in 2025, Ford had to idle its Chicago Explorer line because it couldn’t get the rare earth magnets for basic vehicle parts.
The implications extend deep into the modern defense-tech stack. Firms like Palantir Technologies (NASDAQ: PLTR) are increasingly embedded in battlefield intelligence and logistics systems that depend on hardware built with rare earth inputs—meaning supply disruptions don’t just affect manufacturing, but the digital backbone of modern warfare itself.
That was a civilian automaker with some buffer. Defense supply chains run even tighter, with longer lead times and far less room to adjust. It’s not just heavy defense either. Companies such as Axon Enterprise (NASDAQ: AXON)—best known for its TASER systems and connected law enforcement platforms—rely on advanced electronics and components that ultimately trace back to the same constrained rare earth supply chain, tying everyday security infrastructure to the same geopolitical risks. And with the latest conflicts across the Middle East and beyond, the consequences are becoming more dire by the day.
What REalloys Built While The West Watched
Most of the rare earth industry spent years reacting as China pulled the strings. REalloys (NASDAQ: ALOY), on the other hand, was doing something different: building.
The company’s operations in Euclid, Ohio, grew out of years of work with the U.S. Department of Energy and Department of Defense. While other players chased mining permits, REalloys focused on the harder problem: building the metal-making and alloying capabilities that turn processed rare earths into defense-grade inputs.
That meant working with suppliers, developing processing technology, training metallurgists, and qualifying output to military specs. That kind of work takes years, even when you know what you’re doing.
On the processing side, REalloys locked in an exclusive offtake covering 80% of the output from North America’s only heavy rare earth processing plant.
That facility is run by the Saskatchewan Research Council, which spent over 12 years working with rare earth clients at pilot and lab scale before breaking ground.
In 2020, Beijing passed export controls that blocked sales of rare earth processing technology to countries it didn’t consider allies. That should have killed the project.
Instead, the team built custom furnaces, automation systems, and separation chemistry from core physics and chemistry — requiring no Chinese technology transfer at any step.
What came out of that constraint surprised even the engineers. Because the team built the processing side from scratch rather than copying Chinese designs, the facility now runs on AI-driven controls that handle thousands of adjustments around the clock.
A comparable Chinese facility employs dozens of workers managing manual processes across an eight-hour shift. REalloys’ supply chain produces metals at higher purity with a fraction of the labor.
The Saskatchewan government funded it, construction began over five years ago, and REalloys’ exclusive agreement means the bulk of everything that plant produces flows to Ohio, where it becomes the finished alloys that defense contractors need.
Every step takes place on North American soil, with no Chinese technology, chemicals, or capital involved in any critical part of the chain.
Why Catching Up From Here Could Take Years, Not Months
The gap between REalloys and the rest of the Western world is wider than most people realize. And it’s not simply a matter of money.
Mining rare earths and processing them are completely different skills. The companies making headlines in this space are mostly miners. They know how to pull ore out of the ground.
But turning that ore into defense-grade metals requires dozens of chemical steps, each with hundreds of stages needing tight control. You can buy the best mining rights on the planet and still have no way to turn the rocks into something the Pentagon can use.
Some companies bought processing gear from China before the export controls hit. But even with the hardware, many still can’t run it properly because they bought equipment without the know-how to operate it.
The dependency on China goes deeper than just a lack of skills, though.
Chinese-made furnaces need graphite parts sourced only from Chinese makers, and those parts can wear out several times a week.
If your plant runs on Chinese hardware, you’re one supply cut away from going dark — no matter how much domestic ore you have sitting in a warehouse.
Tim Johnston, REalloys’ co-founder, puts the catch-up timeline at three to seven years for a credible competitor starting today.
That means building separation capabilities, developing oxide-to-metal conversion, qualifying with defense buyers, and doing all of it without Chinese technology or parts. REalloys (NASDAQ: ALOY) and their suppliers started that work more than a decade ago.
The Deadline That Changes the Math
All of this matters more now because of the regulatory clock that is about to run out.
On January 1, 2027, updated DFARS rules take effect, banning Chinese-origin rare earth materials from American weapons systems. The ban covers every stage: mining, refining, separation, melting, and fabrication.
Earlier loopholes let contractors melt Chinese oxides in a third country and call the output non-Chinese, but that workaround ends in 2027. The Pentagon is backing the rule with compliance checks on every covered contract, random spot-checks, and False Claims Act liability.
That means every company selling into the defense base will need a verified, non-Chinese source for rare earth metals and magnets. Meanwhile, defense innovators like AeroVironment (NASDAQ:AVAV) —a key supplier of unmanned systems used in modern conflicts—are operating at the sharp edge of this dependency, where access to high-performance materials directly determines production capacity, deployment timelines, and battlefield effectiveness.
Meanwhile, China’s own factories now use roughly 60% of their rare earth output for domestic EVs, wind turbines, and electronics.
Whatever surplus gets exported then moves through monthly licensing that Beijing adjusts depending on the political temperature. The IEA has flagged this as a core vulnerability for any country that depends on Chinese supply.
New Heavy Rare Earth Facility
REalloys’ recent announcement fills in the last piece of the puzzle. The company will use roughly $40 million from its recent offering to build the Heavy Rare Earth Metal Facility — delivering materials first assembled and tested in Saskatoon, then moved to REalloys’ Ohio operations.
From there, it’ll be available to serve U.S. defense customers and supply Defense Logistics Agency stockpiles. First operations are aiming for early-to-mid 2027, with full commercial scale expected by mid-to-late 2027.
REalloys expects to receive roughly 400 tonnes of defense-grade rare earth metals per year once the processing facility reaches full production, scaling to about 600 tonnes by 2028-29.
Washington has signaled their confidence in REalloys’ capabilities too: the U.S. EXIM Bank issued a $200 million letter of intent to support the company’s broader supply chain development
That’s in addition to their contract worth up to $1.7 million announced by the Department of Defense to fund the design of a processing facility to produce metals for weapons and electronics
Now, as the company approaches Phase 2, it plans to target an annual output of about 18,000 tonnes of heavy rare earth permanent magnets.
As the West finally faces the consequences of relying on China for these critical resources, strategic moves like those by REalloys may help America close the gap.
Here’s the honest picture: China will still process the bulk of the world’s rare earths for years to come. The goal was never to take half the market from Beijing. After three decades of state-backed dominance, that isn’t realistic on such a short timeline.
The goal is to lock in enough non-Chinese capacity to keep the Western defense base running on its own and give the U.S. real leverage where it has none today. REalloys is one of a small number of companies working with the U.S. government to achieve this goal.
That required someone to start building before the rare earths crisis made it obvious, and to keep building through every cycle where Chinese pricing threatened it.
REalloys appeared to see this crisis coming years ago. With their recent funding news, the path from plan to production is fully paid for — and the 2027 deadline is now less than ten months away.
By. Charles Kennedy
