The exceptional properties of Nd-Fe-B magnets make them essential in key technologies, including renewable energy systems, electric vehicle motors, wind turbine generators, and consumer electronics [1]. As e-mobility and renewable energy sectors expand, demand for these high-performance magnets is projected to increase significantly [2]. However, their production relies heavily on rare earth elements (REEs), presenting challenges due to supply security, market fluctuations, and environmental concerns associated with rare earth mining, which remains largely monopolized outside Europe. Research efforts have targeted reducing heavy rare earth (HRE) dependency in magnet production and developing recycling methods to reclaim REEs from industrial residues, pre-consumer scrap, and end-of-life products [3-5]. Despite progress, scalable industrial applications of these strategies are still under development.

Our study focuses on the functional recycling of Nd-Fe-B magnets from diverse waste streams, demonstrating their potential to replace primary magnets across various applications without performance loss. This approach not only mitigates costs and supply risks but also advances a more sustainable circular economy.

To achieve this, Nd-Fe-B magnets were sourced and recycled by functional recycling process from end-of-life products (e.g., electric motors, wind turbines, and traction motors) and production wastes. After collection and recycling, three prototypes (Pedelec, e-Scooter, and hoverboard) were examined for their magnetic property profiles and ease of dismantling. The magnetic properties of the recycled magnets were compared with target values obtained from primary magnets extracted from the investigated devices. Results indicate that the recycled magnets possess sufficient magnetic characteristics, making them suitable substitutes for primary magnets in these applications. Motors in these devices were reassembled using recycled magnets in place of the primary ones. Motor performance tests with a speed-controlled load machine showed that motors using recycled magnets operated effectively, with performance and efficiency comparable to those using primary magnets (Figure 1). These findings confirm the viability of using recycled magnets in e-mobility applications.