Abstract

Rare earth elements (REE) are vital to modern technologies—from smartphones and electric vehicles to wind turbines—but their extraction and refining often cause severe environmental damage. This paper explores how Microbial AI, bioleaching, and digital twin technologies can transform the manufacturing process of all 17 rare earth elements through sustainable, data-driven innovation. By integrating machine learning algorithms with engineered microbes that selectively bind or extract specific metals, and by using digital twins to simulate, optimize, and monitor microbial bioreactors in real time, we can dramatically reduce waste and energy use. The convergence of biology, AI, and cyber-physical modeling marks a new era in eco-industrial manufacturing, offering a blueprint for cleaner, smarter, and circular rare-earth production systems essential for a sustainable technological future.