USA Rare Earth expects its Round Top heavy rare earth elements mine in Texas to reach full production by the end of 2028, potentially strengthening US supply of dysprosium and terbium for permanent magnets, defense systems, electric vehicles, and advanced manufacturing.
USA Rare Earth Accelerates Round Top Development
USA Rare Earth, known as USAR, is moving ahead with an accelerated plan for the Round Top HREE project in Texas. Chief executive Barbara Humpton said the company aims to complete all feasibility studies this year, build the mine next year, and reach full production by late 2028.
The revised schedule reflects a faster development path than previously indicated. USAR now expects to complete its Definitive Feasibility Study in 2026, compared with an earlier target of 2027. For the US rare earth supply chain, the timing is important because heavy rare earth elements remain among the most strategically sensitive materials in the magnet and defense supply chain.
Heavy Rare Earths Gain Strategic Importance
Round Top is focused on heavy rare earth elements, including dysprosium and terbium. These materials are critical for high-performance magnets because they improve heat resistance and magnetic stability in demanding applications such as electric vehicle motors, wind turbines, robotics, aerospace systems, and defense technologies.
USAR’s Accelerated Mining Plan uses a four-step process covering mining, crushing, heap leaching, and solvent extraction. The company says this flowsheet avoids several capital- and energy-intensive steps, including grinding, flotation, magnetic separation, roasting, and acid bake. If commercially proven at scale, the simplified process could improve project economics and shorten the development cycle.
AI and Digital Twins Support Rare Earth Processing
USAR is also using quantum computing, artificial intelligence, and digital twins to optimize material research and upstream operations. Digital twins can help model rare earth separation systems and improve process efficiency before full-scale production begins.
The company’s broader strategy also includes downstream magnet manufacturing. Its Stillwater, Oklahoma, magnet plant came online after completing commissioning in the first quarter, giving USAR a stronger position across both rare earth mining and magnet production.
Market Impact
○ Impacted Metals: Dysprosium oxide, terbium oxide, heavy rare earth elements, rare earth magnet materials
○ Direction: Mixed
○ Time Horizon: 2026–2028
○ Affected Industries: Permanent magnets, electric vehicles, wind power, defense, aerospace, robotics, rare earth separation, critical minerals supply chains
○ Related Price Reports: Rare Earth Weekly Price Report
○ Watch Item: Monitor whether USA Rare Earth completes the Round Top DFS in 2026 and keeps mine construction on schedule for full production by late 2028.
SuperMetalPrice Commentary
Round Top is important because it targets the heavy rare earth elements that are hardest to replace in high-performance magnets. Even if full output is still several years away, the project supports the US effort to build a more integrated rare earth supply chain from mine to magnet.
The key market question is not only whether Round Top can start production by 2028, but whether its processing route can deliver reliable dysprosium and terbium supply at commercial scale.
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