In the setting where you can make troops and massive space ships from thin air, it is not impossible to create a massive army hidden from the sight of the rest of the galaxy. Or perhaps they are from far far away place, that burned brother got his visions and then they arrived in the middle of ongoing war between Republic and Empire?
Maybe they don't have Jedis and Sith, but instead they have cultivated the Force to other direction? Then that dude got visions and they began wondering who are those Force wielders.
If you think about KotOR, there was quite a similar situation.
Or, perhaps the best answer to all these questions: MAGIC