ADVANCED MATERIALS & PROCESSES | JANUARY 2026 6 METALS | POLYMERS | CERAMICS Technology (TU Delft), the Netherlands, are investigating bacterial spores as an important candidate in the field of engineered living materials (ELMs). By embedding Bacillus spores within ELMs, the researchers are creating living materials that not only endure harsh environments but can also be programmed to perform specific tasks. Certain bacterial species can switch into a dormant and metabolically inactive state, called a spore, which is extremely resistant to heat, dryness, and chemical stress. The autonomously grown ELMs have a wide range of potential applications, such as detecting disease biomarkers and catalyzing the breakdown of environmental pollutants. They could also function as self-healing composites. In the future, these new substances could even be used as a sustainable replacement for fossil-based materials, according to the team. To fabricate the material, the scientists combined two bacterial species: Komagataeibacter rhaeticus and Bacillus subtilis. K. rhaeticus produces strong bacterial cellulose fibers that act as a protective physical barrier while Bacillus contributes its spore-forming capacity. The mixture creates a robust NEW PROCESS MAKES NEODYMIUM MAGNETS Researchers at Lawrence Livermore National Laboratory (LLNL), Case Western Reserve University (CWRU), and Ames National Laboratory created a new method for neodymium magnet fabrication that generates high-purity material at high efficiency. Although the U.S. has neodymium deposits, refining the material has remained out of reach due to the energy-intensive process, permitting restrictions, and the lack of a qualified workforce. The new technique could address all three barriers, according to the team. It operates based on chloride molten salt electrolysis. Neodymium enters the system attached to chloride ions. Next, the electrolysis setup uses electricity to split the incoming molecules apart, pulling the neodymium to one end of the system (the cathode) and chloride to the other (the anode). “We hope this method becomes a cornerstone for domestic production of neodymium magnets,” says LLNL scientist Eunjeong Kim. “It can enable a truly U.S.-based ‘mine-to-magnet’ manufacturing chain from rare earth mining and separation to final magnet fabrication, reducing reliance on overseas processing.” Compared to traditional refining, the new process avoids two energyintensive steps and does not produce harmful gases as a byproduct. Because the anode design prevents degradation, the device can operate continuously. Chloride molten salt electrolysis could also be extended to other rare earth metals critical for energy technologies, say scientists. CWRU led the electrochemical design and process modeling. LLNL contributed materials characterization and anode fabrication, and Ames used the material produced to fabricate magnets that are comparable to industry standards. Now, CWRU is working to scale up the electrolysis setup design while LLNL is testing new deposition approaches to further stabilize the anode. llnl.gov. ENGINEERED LIVING MATERIALS LOOK PROMISING Scientists at Delft University of The new process flow for magnet fabrication requires much less energy than traditional methods. Courtesy of Dan Herchek. This wet film of cellulose is composed of cellulose-producing bacteria Komagataeibacter rhaeticus and Bacillus spores. Courtesy of Jeong-Joo Oh/Aubin-Tam Lab. The Composites Institute (IACMI) launched a “Make It In America” outreach campaign to raise awareness of manufacturing careers and help fill 3.8 million jobs by 2030. The effort will educate workers about job opportunities through two programs, America’s Cutting Edge and Metallurgical Engineering Trades Apprenticeship & Learning. iacmi.org. BRIEF
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