Compare NotebookLM with Notion, Obsidian, Recall, Atlas, and Open Notebook to find the best AI research and knowledge management tool for your workflow.
Rare Element Resources (RER) has issued a project update on its Bear Lodge rare earth element deposit in Wyoming, one of the largest known carbonatite-hosted rare earth deposits in North America. According to the update the environmental review and mining site permitting is in progress and is anticipated to be completed by March 2028. The update also states that the demonstration rare earth element (REE) separation plant will commence operations by late summer 2026. It is scheduled to run for up to 12 months and will produce an up to 10 tons of neodymium-praseodymium (Nd/Pr) oxide.
The mineral deposits at Bear Lodge contain both the magnet rare earth materials neodymium, praseodymium, samarium and terbium as well as cerium (Ce), lanthanum, yttrium, gadolinium, europium and dysprosium. All these elements are on the U.S. Geological Survey`s list of 60 critical minerals. The minerals on the list have been identified as critical due to their role in national security or economic development and by their risk of supply chain disruption.
The project details
The vertically integrated Bear Lodge Rare Earth Project encompasses mining of rare earth element (REE) ore which will become feed material for a state-of-the-art commercial processing facility. The facility will produce high-purity separated neodymium-praseodymium (NdPr) oxide using the company`s patented, environmentally friendly technology. It will be designed as a zero discharge facility and will located approximately 40 miles from the mining area.
The full scale commercial processing facility will be built based on the operational, economic, and engineering data derived from the demonstration plant. This US Nuclear Regulatory Commission certified plant is located at Upton, Wyoming.
Ken Mushinski, President and CEO of RER said “The primary objective of a Demonstration Plant is to systematically uncover and resolve mechanical and operational challenges before scaling to a commercial facility”.
He further said “By fine-tuning our primary processing circuit and resolving these filtration inefficiencies now, we are effectively de-risking our commercial trajectory. Once this front-end optimization is complete, the primary circuit will continuously feed our completed separation circuits to yield high-purity NdPr.
The separation process
According to the company the proprietary separation process involves four steps. It commences by crushing and screening of the feed sample to 1mm size followed by counter-current leaching and selective precipitation, to chemical digestion and solvent extraction, and finally to REE separation and refining.
The final REE separation and refining process involves multiple steps, these remove the Nd/Pr (at greater than 99.5 percent purity) as well as samarium, europium, gadolinium, lanthanum and heavy rare earth concentrates.
The company states that it has done extensive laboratory bench-scale and pilot plant testing on metallurgical processes to recover saleable rare earth products and has been granted two patents on its metallurgical processing. These involve removal of thorium from REE containing acidic solution, as well as the selective extraction of REEs using oxalic acid. These patented processes have been further advanced in collaboration with General Atomics, the company’s majority shareholder.
Supply chain context
The United States currently has limited domestic capacity for separating and processing rare earth elements into refined oxides or metals. Mountain Pass in California remains the only operating rare earth mine in the country, though its concentrate is largely shipped to China for separation (which accounts for 91 percent of the global refined output). Projects like Bear Lodge are positioned as potential contributors to a more complete domestic supply chain, from ore to separated material.
Although permitting timelines, metallurgical recovery rates, and sustained financing are the primary variables that determine whether a deposit moves from resource estimate to operating mine.
Metal additive manufacturing continues to expand beyond aerospace prototypes and into production-focused energy systems. That shift gained momentum this week as Velo3D and gas turbine developer Aurelia Technologies unveiled a partnership aimed at bringing 3D printing deeper into next-generation turbine development.
The companies plan to evaluate, qualify, and eventually manufacture turbine components using additive techniques. Their goal extends beyond experimentation. They want to simplify designs, shorten development cycles, and build a more resilient supply chain for future turbine programs.
The collaboration reflects a broader trend across U.S. manufacturing. Engineers increasingly use additive manufacturing to solve practical production challenges rather than showcase technological novelty. Faster iteration, fewer components, and lower inventory exposure now drive many adoption decisions.
Designing out complexity
Aurelia develops small-scale gas turbines designed to operate efficiently while accommodating multiple fuel types. As its turbine platforms evolve, the company sees additive manufacturing as a way to remove unnecessary complexity from critical assemblies.
Instead of assembling numerous individual pieces, engineers can consolidate multiple components into a single printed part. That approach reduces fasteners, minimizes interfaces, and lowers the risk associated with tolerance stack-ups.
The result could improve durability in demanding environments where turbines face extreme temperatures and mechanical stress.
“Additive manufacturing allows us to simplify designs, reduce failure points, and move faster,” said Karol Hricisak, director of technology at Aurelia Technologies. He added that the company remains grounded in established turbomachinery principles and proven materials science.
Reducing part counts also supports maintenance objectives. Fewer connections can translate into fewer potential failure points throughout a turbine’s operating life.
Testing to production
The partnership will unfold through several phases. Early efforts will focus on determining which turbine components benefit most from additive production.
The companies also plan to assess suitable alloys and refine manufacturing processes before advancing toward qualification activities. The long-term objective involves low-rate initial production using Velo3D’s Sapphire XC metal additive manufacturing platform.
Engineers will examine whether additive methods can improve manufacturability while reducing lead times for complex parts.
Unlike conventional production methods, additive manufacturing can accommodate geometry changes without extensive tooling modifications. Design updates that traditionally require months could move into production within weeks.
Strengthening domestic supply chains
The initiative also addresses supply chain concerns that continue to affect advanced manufacturing sectors across the United States.
Traditional turbine production often depends on long-lead forgings, specialized tooling, and significant inventory commitments. Additive manufacturing offers an alternative path that can reduce those dependencies.
By producing components closer to demand, manufacturers can respond more quickly to engineering changes and shifting market requirements.
Velo3D said Aurelia selected the company because of its experience in metal additive manufacturing and its structured approach to qualification and production scaling.
“Advanced energy systems are pushing the limits of traditional manufacturing,” said Michelle Sidwell, Velo3D’s chief revenue officer. She said additive manufacturing delivers the greatest value when engineers incorporate it early in the design process.
As the initial work progresses, both companies will evaluate additional applications and opportunities to expand the collaboration. The effort highlights how additive manufacturing increasingly serves as a practical engineering tool for next-generation energy and propulsion systems.
Helios Horizon, a Florida-based nonprofit, has completed what it claims is the first piloted flight of an electric aircraft using solid-state batteries.
On June 5, founder and chief test pilot Miguel Iturmendi conducted a series of short test flights at Zephyrhills Municipal Airport in central Florida aboard a modified Pipistrel Taurus motor glider designated as the Helios Horizon.
The aircraft, previously equipped with lithium-ion batteries rated at 260 Wh/kg, was reconfigured to run on solid-state batteries delivering 410 Wh/kg.
According to the organization, these new cells are smaller than typical lithium-ion packs used in modern electric vehicles yet provide 60 to 80 percent greater energy density.
Helios Horizon performs first flight with solid-state batteries
Solid-state batteries replace the flammable liquid electrolyte found in conventional lithium-ion cells with a solid material.
This design allows for enhanced thermal stability and resistance to physical damage such as punctures. The batteries can draw power from standard AC electrical sources without specialized charging infrastructure. In flight, the aircraft can supplement its energy through integrated solar panels and by operating the propeller as a wind turbine during non-powered segments.
According to Helios Horizon, their solid-state batteries charge from near-empty to 80 percent capacity in less than 15 minutes. The organization is also aiming for further improvements of around 40 percent in energy density within two years.
“For the first time, we have a battery technology that yields the range and charging times necessary to make commercial electric aviation viable, while providing the safety the flying public will demand,” Iturmendi said in a statement.
He added that regenerative techniques, including gliding and windmilling the propeller during descents, “can significantly increase the range of the airplane.”
The June 5 flights primarily validated weight and balance after the battery installation, according to a post from RobbReport. The new power system performed better than expected during sustained operation, though specific range and top speed figures were not disclosed.
The future of solid-state battery aircraft
The Helios Horizon previously set a class altitude record at 24,000 feet. The team now plans stratospheric flights later this year, targeting altitudes above 40,000 feet—higher than typical passenger airliner cruise levels. Iturmendi believes the solid-state batteries will enable these missions on a single charge.
At this stage, the Helios Horizon serves as a technology demonstrator to illustrate potential gains in range and endurance for electric propulsion. While not intended for immediate commercial production, the project highlights progress toward practical electric aircraft that address key limitations in energy storage and safety.
The achievement arrives amid broader industry efforts to develop viable electric and hybrid propulsion for aviation. Solid-state technology has long been viewed as a potential breakthrough, promising higher performance and improved safety margins over current battery chemistries. Helios Horizon’s test marks a tangible step in applying that technology to a manned aircraft.
L’intelligence artificielle va-t-elle remplacer ou sublimer nos capacités ? Comment la « GreenTech » peut-elle nous aider à relever le défi climatique ? Pour toucher du doigt ces réponses, direction Viva Technology ! Le plus grand salon de la tech et des startups en Europe ouvre ses portes au...
The carmaker will follow Tesla in making components for large batteries used by electric utilities, data centers and other businesses to handle fluctuations in power supply and demand.
The carmaker will follow Tesla in making components for large batteries used by electric utilities, data centers and other businesses to handle fluctuations in power supply and demand.
The main active ingredient in the storage batteries that General Motors plans to produce is sodium, which is cheaper and easier to process than lithium.
Login
