Magnesium (Mg) metal is a strategically important material in both Australian and global critical minerals supply chains, underpinning applications in lightweight alloys, defence, transportation, and emerging energy technologies. However, global Mg metal production remains highly concentrated and largely dependent on the Pidgeon process – a batch-based vacuum thermal reduction method developed in 1940s. High energy and labour intensity, combined with short equipment lifetimes, make the process poorly suited to secure, scalable, and low-carbon magnesium production. Australia has abundant magnesium resources, so developing advanced processing technologies presents a key opportunity to strengthen sovereign production capability and diversify global supply. Continuous vacuum technology, known as Continuous Vacuum Retort (CVR), has been developed by CSIRO and demonstrated at pilot scale as a transformative alternative for Mg metal production through the Pidgeon Process. A pilot-scale CVR facility has been designed, built and tested for continuous silicothermic reduction of MgO. Operating under stable high-temperature and deep vacuum conditions, the system enables continuous feed input, efficient metal vapour extraction, and automated residue discharge. Selective condensation using temperature-controlled condenser tubes facilitates effective separation of Mg from impurities. The process has produced high-purity Mg metal (>98 per cent, Figure 1) operating at 1.5 kg/h, exceeding typical batch process performance. Continuous operation over 36 hrs has also been demonstrated. Analysis of residual by-products indicates they are suitable for use in cement applications, supporting improved resource efficiency. From a supply chain perspective, transitioning to continuous processing offers significant advantages, including improved energy efficiency, enhanced equipment durability, and increased operational safety. These benefits support scalable, lower-emission production pathways critical to both Australia’s ambition to develop domestic magnesium capability and the global need for more resilient and diversified supply chains. Beyond magnesium, the CVR platform shows strong potential for applications to other critical minerals/metals.