Technology
Advanced Metallurgical Processing
4f Orbital employs advanced metallothermic reduction technologies to convert rare earth fluorides into:
- Rare Earth Metals
- Eutectic Alloys
- NdFeB Magnet Alloys
- Magnet Grade Powders
The process delivers:
- High Purity
- Low Carbon Content
- Improved Yield
- Lower Energy Consumption
- Enhanced Magnet Performance
AI Manufacturing Center
Industry 4.0 Meets Rare Earth Processing
4f Orbital integrates Artificial Intelligence into:
- Process Automation
- Predictive Maintenance
- Alloy Design
- Inventory Management
- Quality Assurance
- Supply Chain Logistics
This creates a smarter, more efficient manufacturing ecosystem.
General Operations
In our plant, we adopt to use AI to:
- Automate the melting process using temperature monitors and cameras
- Determine melting and mixing recipes for customer specified alloys and powders
- Automate production controls to maintain consistency, high production yields, electrical power efficiencies
- Monitor operating hours to determine equipment preventive maintenance
Our AI powered administration management platform functions to:
- Automate the logistics of the raw material imports and the export of finished products in accordance with U.S. Customs and Foreign Trade Zone transactions
- Automate accounting transactions from customer orders to sales invoices
- Control inventory using material requirements planning
Environment, Health & Safety
4f Orbital’s operations will comply with all EPA, OSHA, and state regulatory requirements. Required permits will address wastewater, slag handling, and particulate control. Safety, environmental stewardship, and responsible waste management are core operating principles.
The 4f Orbital calciothermic method to reduce rare earth fluorides into rare earth metals, alloys and powder does not use any carbon or graphite materials, and does not emit any environmentally sensitive greenhouse gas or perfluorocarbon emissions that are emitted by the electrolysis method.
Research and Development
Innovative solutions are needed to mitigate supply chain vulnerabilities and address both near-term challenges and provide the scientific and technological groundwork to address mid-to-long-term challenges in the NdFeB magnet supply chain.
The Department of Energy funds research that seeks to diversify and expand the supply of rare earth elements from a wide range of sources that are economically viable and minimize environmental impact, including the co-production of rare earth elements, alternative magnet materials, manufactured magnets, and end-use technologies that increase material and manufacturing efficiency across the supply chain, including efficient use and processing, as well as extending the lifetime of materials; and to promote a circular economy to remanufacture, refurbish, repair, reuse, recycle, and downcycle materials and components, while incentivizing collection.
Other research opportunities with universities and interested parties, domestic or foreign, may exist to improve the reduction of rare earths into metal and alloys, the casting of magnet alloys to optimize the grain sizes for producing powders, and to improve the milling of magnet powders.
Opportunities with joint venture partners may include technology development collaborations or downstream manufacturing arrangements that strengthen the company’s position.