The project aims to develop a sustainable alternative to rare-earth metals used in electric vehicle (EV) permanent magnets by focusing on a promising rare-earth-free candidate known as tetrataenite L10-FeNi phase. To circumvent the kinetic requirements imposed by natural tetrataenite formation in meteorites through ultraslow cooling after millions of years, this project pioneers a strategic combination of alloy engineering, modern metallurgy, and thermomechanical treatments to replicate this structure in cast FeNi alloys. Our method seeks to overcome the diffusion constraint with an out-of-the-box approach by investigating the viability of modifying the atomic arrangement, optimizing the material texture, generating mechanical driving forces, and strategic application of heat treatment. Developed in collaboration with Dana Incorporated, an industry leader in automotive electrification, the project ensures that the resulting manufacturing scheme is not only scientifically robust but also practical, scalable and aligned with both Canada’s Critical Mineral Strategy and Net-Zero Emissions targets. By capitalizing on Canada’s significant nickel production, the project supports domestic circular economy and mitigates risks related to geopolitical uncertainties affecting rare-earth metals. Dana’s expertise in automotive electrification ensures rapid commercialization, while CanmetMATERIALS, Natural Resources Canada will facilitate a seamless transition from research to production lines of metal manufacturers. By developing rare-earth-free permanent magnets, this project aims to enhance Canada’s EV manufacturing capabilities, promote sustainability, and fulfill national environmental goals. The project is a strategic opportunity that could position UNB as a leader in the development of new magnetic materials and in HQP training through state-of-the-art infrastructure development.