Currently, India’s foundry market for automotive components is small (only 10 percent of total foundry market — 10 million of cast iron + aluminium) in comparison to USA’s foundry market, which is at 14 million tonnes per annum, of which 3.3 million is aluminium (24 percent). With an increasing focus on higher performance with better safety and lower emission, this gap is going to shrink in the coming years, anticipates Ajay Kapur, CEO – Aluminium & Power Business, Vedanta Aluminium.

“There is immense scope for Indian aluminium producers to tap into the emerging market in the automotive sector,” said Kapur. Vedanta Aluminium was the first in India to supply PFA (primary foundry alloy) to the domestic auto sector. Before, the launch of PFA by the company, India’s entire PFA demand was being met through imports, even though the country has the world’s second-largest aluminium production capacity. Looking at the potential of the auto market and its import dependency, the company decided to tap into the opportunity and develop indigenous capabilities at its state-of-the-art facilities in Jharsuguda and BALCO to meet that demand. Currently, the company has a PFA casting capacity of 240KT spread across its plants in Odisha and Chhattisgarh.

“Primary aluminium producers develop PFAs which are customised to suit the exact needs of automakers in terms of performance, strength, durability, etc. Significant R&D and technical expertise go into developing PFAs, resulting in excellent metal quality and outstanding castability, which makes these alloys the preferred choice for the automotive industry,” explained Kapur. PFAs are ideal for aluminium alloy wheels, cylinder heads and brakes. The company also anticipates that with an increased focus on reduction of vehicle weight with higher safety performance, automotive parts critical to safety will be made from PFA instead of cast iron to offer higher strength and nearly double absorption of crash energy. “Besides, aluminium PFAs will always have the added advantage of cost-saving on fuel and maintenance,” added Kapur.

Vedanta Aluminium has started steadily supplying PFAs to OEMs and ancillaries in wheel manufacturing in India. “Our proactive move to expand business on this front helped us on-board some of the most reputed equipment manufacturers and auto ancillaries as our clients, and we have received a very positive response from them. Encouraged by that, we will soon look to expand our alloy portfolio for supporting manufacturing of cylinder heads, ABS brakes and certain key applications where traditional materials can easily get substituted with aluminium alloy. We are also exploring prospects of long-term investments by auto ancillaries near our aluminium smelters so that they may leverage cost savings in terms of freight, re-melting and electricity,” said Kapur.

The company, according to him, is well-positioned to cater to the current and emerging needs of the Indian auto sector, offering a broad range of products that find usage across the automotive value chain – from casting to extrusion. “When choosing suppliers for alloys, automotive players should look for companies having high-quality casting facilities, sophisticated R&D facilities and technological prowess for developing customised high-performance alloys for their specific needs, and finally, having robust after-sales technical support; USPs that have earned us the trust of our clients,” he added.

Aluminium is the second most used metal in the world after steel, today, and, according to Kapur, it has the potential to become the most important commercial metal in the future. “Most developed countries have already designated aluminium as a core industry. Aluminium holds strategic importance for the economy as the metal of choice for all kinds of transportation, power, aerospace, defence, building and construction needs. So, given the role it plays in supporting the core sectors meet the Government’s ‘Make in India’ initiative, we expect its application to only expand with time,” said Kapur.

The metal’s usage in the transportation sector has been rapidly increasing as it offers an environment-friendly and cost-effective way to increase performance, boost fuel economy and reduce emissions while maintaining or improving safety and durability. Aluminium is substantially lighter than its counterparts, offering a significant reduction in weight, which has a direct impact on fuel consumption and carbon emissions.

The metal also has a higher strength-to-weight ratio compared to traditional materials that enable it to absorb twice the crash energy of mild steel, ensuring that vehicular performance enhancements do not come at the cost of safety. “Further, nearly 90 percent of all the aluminium used in a vehicle is recycled at the end of its lifecycle. The energy required to recycle aluminium is only five percent of the energy required to produce the metal. With all these advantages, aluminium can play a pivotal role in the changing face of the automotive sector,” said Kapur.

Aluminium alloys are used by the Indian auto industry majorly as alloy wheels. Around 95 percent of two-wheelers include aluminium, averaging at 7kg per bike, taking total consumption of aluminium alloy in this segment to 115KTPA (kilo tons per annum). Whereas, only 20 percent of four-wheelers use aluminium, majorly in high-end models, which max out at 40kg per car. “The crux of the matter is, in India, we are yet to explore more applications of aluminium in the automotive industry akin to our global peers. For example, in developed countries, around 21 PFAs are used in the automotive segment to achieve light-weighting in the form of various auto parts and components. In India, we majorly use PFAs only for manufacturing alloy wheels and to some extent, for cylinder heads. So, there is immense potential for usage of aluminium in other auto parts like engine, suspension, front end carrier, instrument panel support, rear frame, chassis and many more,” said Kapur.

Shortly, the company expands its alloy portfolio for supporting manufacturing of cylinder heads, ABS brakes and certain other applications where currently steel or iron is being used but can be substituted by suitable aluminium alloys to provide additional benefits. As the market for aluminium alloys in automotive segment expands with inclusion of newer applications, Vedanta Aluminium will look for opportunities to leverage its technological expertise and R&D capabilities to develop products customised to the needs of the market. Vedanta Aluminium is also open to collaborating with the downstream industry, to unlock the entire potential of aluminium used in the auto sector and cater to the rapidly evolving aluminium requirements of the Indian automotive industry.

In the Indian automotive market, one of the biggest challenges faced today is the increasing imports of auto components from China and other countries. The size of the auto components imports was USD 17.6 billion in FY19. Asia, the largest source of imports for Indian auto-components, had a share of 61 percent followed by Europe at 29 percent; North America at eight percent; Latin America and Africa at one percent each in FY19. China, with 27 percent, enjoyed the status of the largest exporter in the Indian automotive market.

“The potential of the aluminium industry should be acknowledged and recognised as a core sector with a National Aluminium Policy that will encourage, protect and boost the domestic aluminium industry. The domestic capability needs to be harnessed for critical sectors of national importance like defence, aerospace, aviation, transportation, infrastructure, electrification, housing, etc. We must make the vision of ‘Make in India’ a ground reality in these sectors, leveraging the potential of the entire aluminium value chain, from mining to end usage. Besides enhancing domestic capacity and reducing import dependency and subsequently trade deficit, it will also generate huge employment opportunities in our country which has a deep talent pool that needs to be capitalised for the realisation of our vision of a USD5 trillion economy. We are on the right path, but there is still a long way to go,” said Kapur.

The global economy is swiftly moving towards a cleaner, greener and more sustainable lifestyle. For more than a decade now, concerns about fuel efficiency have encouraged OEMs to replace steel with aluminium in vehicle bodies, doors, trunks, hoods, bumpers, crash boxes, brakes and wheels. With the advent of electric vehicles (EV), OEMs worldwide are focusing on exploring and applying new uses of aluminium. The need for lightweight battery casings and heat exchangers in electric vehicles, combined with autonomous vehicles’ demands for high visibility and structural integrity, is expected to exponentially increase the use of aluminium in cars, trucks and buses from now on. “Using aluminium in EVs has several advantages, foremost amongst which is the distance travelled per charge. Lighter the vehicle, the longer its range. Coming to better battery life, thanks to the metal’s thermal and anticorrosion properties, aluminium is ideal for battery frames. Demand for aluminium will also rise on account of infrastructure for serving EVs since the metal is commonly used as a housing material for EVs charging stations as well. While India is waking up to this future of automobiles, partnerships between different automotive industry bodies/institutions and auto companies for sharing knowledge and expertise will help fast-track development of electric vehicles in the country,” said Kapur. MT

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Battery Smart (Upgrid Solutions) has raised USD 15 million in debt funding from Mirova, a sustainable investment affiliate of Natixis Investment Managers.

The facility is intended to accelerate the expansion of the company’s Battery-as-a-Service (BaaS) infrastructure across India. The capital will specifically support the growth of partner-led swap stations in urban and semi-urban markets, enhancing service for high-usage segments such as last-mile delivery and passenger mobility.

Since launching its first station in New Delhi in 2020, Battery Smart has developed one of India's largest battery-swapping networks. It has setup more than 1,600 stations across 50 cities, wherein EV drivers can swap a depleted battery for a fully charged one in approximately two minutes, significantly reducing the downtime associated with traditional plug-in charging. By separating battery costs from vehicle ownership, the model reduces upfront vehicle purchase prices and improves daily earnings for gig economy drivers.

This transaction marks Mirova’s third investment in the Indian market, following previous commitments to companies like Revfin. The investment is part of Mirova's broader strategy to support high-impact climate solutions in emerging economies.

Pulkit Khurana, Founder and CEO, Battery Smart, said, “This financing marks an important step for us as we continue to scale our battery-as-a-service network across India. With Mirova’s support, we aim to accelerate network expansion and further our focus on making electric mobility more accessible, affordable, and inclusive for drivers across the country.”

Priyanka Mehrotra, Investment Director, Mirova, added, “This transaction marks our third investment in India, thus reflecting continued commitment to supporting high-impact climate solutions in emerging markets. We are pleased to support the next phase of Battery Smart’s growth, rooted in a scalable and operationally efficient model that addresses both environmental and economic challenges, particularly in last-mile mobility.”

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China-headquartered PATEO Connect Technology has announced two major strategic partnerships – AUMOVIO and NVIDIA – during the Beijing International Automotive Exhibition, focusing on the global expansion of artificial general intelligence (AGI) and high-performance computing in the automotive sector.

The leading Chinese provider of intelligent vehicle connectivity solutions, specialising in AI-enabled, cloud-based infotainment, Operating Systems (PATEO OS) and hardware for automakers

PATEO entered into a memorandum of understanding (MoU) with AUMOVIO Holding China Co. The parties intend to jointly develop cross-domain integration and AGI technologies. The agreement focuses on leveraging high-computing SoC platforms and integrated cockpit-driving domain controllers for R&D. It will utilise global supply chains, OEM resources and manufacturing capabilities. Promoting Software-Defined Vehicle (SDV) domain control and AGI automotive application projects.

The partnership aims to establish a ‘channel + product’ alliance, combining joint investment with technology collaboration to address future market demands for intelligent mobility.

PATEO also confirmed deep collaborations with NVIDIA and a leading New Energy Vehicle (NEV) OEM. To address the demand for computing power in Level 3 and Level 4 autonomous driving, PATEO is developing on-vehicle solutions powered by the NVIDIA DRIVE AGX Thor platform.

As per the understanding, the partnership will implement PATEO’s AI Box on the NVIDIA platform to support vehicle-side deployment of next-generation models. PATEO has received a nomination for a model project representing an integrated ‘software and hardware’ solution. The project marks a commercial application coupling ByteDance's general large model with PATEO’s edge model.

PATEO and its partners have initiated deployment for vehicle-side scenarios, including physical AI, AI agents, and AI emotional agents. The company is also exploring business models such as computing power charging and vehicle-mounted tokens billing.

As automotive intelligence shifts toward being ‘AI-defined,’ PATEO said it continues to execute its ‘AI + Globalisation’ strategy, transitioning large-scale models from verification to mass production.

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Epsilon Cathode Active Materials (Epsilon CAM) has revealed its Gen III LFP Cathode Material, marking a significant non-Chinese advancement in high-energy-density battery chemistry at a commercial scale.

The technology was developed at the company’s Cathode Technology Centre in Moosburg, Germany, an innovation hub supported by a portfolio of over 145 active patents. The breakthrough addresses the global automotive industry's need for high-performance battery materials that offer supply chain diversification and regulatory compliance.

The Gen III LFP material is engineered to provide electric vehicle (EV) manufacturers with claimed performance differentiation through several key metrics:

• Energy Capacity: Achieves a discharge capacity of ≥159 mAh/g.
• Architecture: Features an electrode density of ≥2.51 g/cc, allowing for denser cell architecture.
• Longevity: Delivers 2X cycle life for extended battery pack durability.
• Thermal Stability: Offers proven performance in high-temperature environments.

A primary feature of the Gen III LFP material is its full PFE (Prohibited Foreign Entity) approval. This compliance allows for unrestricted entry into North American battery manufacturing and automotive supply chains, providing a critical advantage as manufacturers seek to meet diversified regulatory mandates.

Vikram Handa, Managing Director, Epsilon Group, said, "This isn't just incremental. With our Gen III LFP Cathode Material, we've engineered a formulation that gives EV makers genuine performance differentiation – more energy per cell, denser electrode architecture and the compliance pathway that matters most for the North American market: full PFE approval."

To support global demand, Epsilon is advancing manufacturing with a planned capacity of 30,000 TPA (tonnes per annum) in India. By combining German research and development with Indian production, the company offers a credible alternative to Chinese dominance in the battery materials sector.

This ‘dual-hub’ strategy allows EV OEMs to mitigate geopolitical exposure and supply chain concentration risks while achieving performance parity with current Chinese alternatives. The Moosburg facility will continue to lead global R&D and product development for successive generations of LFP materials.

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Sterling Tools has entered a technology collaboration with China-based Nanjing Haohang to manufacture Advanced Rider Assistance Systems (ARAS) for the Indian two-wheeler market.

The agreement establishes a framework for Sterling Tools to lead local engineering, manufacturing and sales of ARAS in India. These systems utilise sensors and software to provide real-time alerts, functioning similarly to ADAS in passenger cars but adapted for the specific dynamics of two-wheelers. The partnership aims to address safety gaps in India, where two-wheeler accidents represent a significant portion of road fatalities.

The collaboration has already resulted in the testing and validation of several features on Indian roads. These include Front and Rear Collision Warning, Blind Spot Detection, Lane Change Warning, and Wrong-Side Alert.

Sterling Tools plans to offer these production-ready systems to original equipment manufacturers (OEMs) to support the adoption of intelligent mobility and safety-driven regulations.

Anish Agarwal, Director, Sterling Tools, said, “We are moving toward an era of intelligent mobility. This partnership with Haohang, tailored for the Indian market, equip two-wheeler OEMs with advanced rider assistance technologies that address a critical safety gap. Two-wheeler accidents account for a significant share of road fatalities in India and our collaboration aims to foster a safer environment for the 2W industry and its manufacturers.”

Nanjing Haohang will provide the global technology platform, while Sterling Tools will manage system adaptation for local road conditions. This expansion follows Sterling Tools’ recent investments in EV power electronics and rare-earth-magnet-free motor solutions.

LI Zhipan, General Manager, Nanjing Haohang, added, “India represents one of the most important markets for advanced rider assistance technology, given the scale and safety challenges of its two-wheeler segment. Our collaboration with Sterling Tools allows us to localise our solutions for Indian road conditions and bring validated, life-saving technology to automakers and riders across the country.”

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