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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The BMW Group has entered into a cooperation with Croatia’s Rimac Technology to equip the new all‑electric BMW i7 with advanced battery systems. This collaboration focuses on integrating BMW’s in‑house developed Gen6 technology into the flagship electric sedan, aiming to deliver superior range and faster charging capabilities.

At the heart of this project is the Gen6 lithium‑ion cylindrical cell, specifically the 4695 format, which offers a 20 percent higher volumetric energy density than the prismatic cells used in the previous Gen5 system. By combining the Gen6 cell technology with the established Gen5 module design, the high‑voltage battery enables a significantly increased driving range for the BMW i7. Additionally, the new setup boosts charging capacity and cuts charging time, greatly benefiting customers. The world premiere of this model is scheduled for 22 April at Auto China 2026 in Beijing.

Rimac Technology, a Tier 1 supplier within the Rimac Group, produces these high‑voltage batteries using state‑of‑the‑art equipment at its Croatian facility. The batteries are then delivered ready for assembly to the BMW Group Plant Dingolfing, the sole production site for the BMW 7 Series. Known for its in‑house development of battery systems, e‑axles, electronics and software, Rimac offers highly customisable electrification solutions. This long‑term partnership with BMW marks Rimac’s evolution from a niche supercar supplier to a Tier 1 provider for high‑volume vehicle projects.

Dr Thomas Engelhardt, Senior VP Development High-Voltage Storage and Charging, BMW Group, said, "We are quickly rolling out the technologies of the Neue Klasse across our entire model portfolio – including, of course, in our all-electric luxury sedan. The teams of both companies have developed a tailor-made solution for the new BMW i7. The excellent collaboration with Rimac Technology is a good example of European innovative strength."

Mate Rimac, Founder and President, Rimac Group, CEO and CTO Bugatti Rimac, said, “BMW has always been known for pushing engineering to the highest level, which made this collaboration especially exciting for us. Together, we developed a high-voltage battery system that unlocks the full potential of the new cylindrical cells in record time, delivering significant improvements in energy, range and charging performance. We are proud to now see this system being produced at scale at our new Rimac Campus.”

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AUMOVIO has received a series production order from a European automotive manufacturer for its OLED display unit featuring an integrated under-display camera. The technology, which was recognised as a CES Innovation Award Honoree, will be implemented in a high-volume premium vehicle model.

The system integrates the camera module behind the active area of the OLED display, removing the requirement for visible camera hardware within the vehicle cabin. This architecture utilises a specific pixel design and OLED technology to maintain a seamless visual interface while allowing the camera to function through the display surface.

The technology supports several vehicle functions, including monitoring for driver attention and drowsiness detection. Enabling cabin-based assistance features and facilitating minimalist cockpit layouts by eliminating bulky external modules.

Internal studies conducted by AUMOVIO indicated that drivers prefer discreetly integrated sensors over visible camera modules. The company has positioned this solution to mirror the transition seen in the smartphone industry, where under-display facial recognition has gained high user acceptance.

By localising the camera under the display, the system maintains an optimal angle for driver monitoring without disrupting the aesthetic of the digital cockpit. The OLED technology used provides high contrast and colour accuracy, meeting the standards required for the premium automotive segment.

Pavel Prouza, Head of the User Experience (UX) business area at AUMOVIO, said, "We are very pleased about the customer order, which was placed shortly after the initial innovation presentation. The order is a strong market signal and confirms that we and our strategy are on the right track. We focus on developing state‑of‑the‑art technologies and transitioning them to series production - to increase safety and comfort in mobility with exciting new cockpit designs."

“With the camera invisibly integrated under the active area of the driver display, we have opened the door to the next generation of exciting and minimalistic cockpit designs – while making a major contribution to advancing safety‑relevant assistance features through wider user acceptance," he further added.

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French tier 1 supplier Valeo has commenced production of high-definition (HD) surround-view cameras at its facility in Sanand, Gujarat. The new production line was inaugurated on 3 April 2026 by Marc Vrecko, CEO of Valeo’s Brain Division, marking an expansion of the company’s vision system manufacturing in India.

The Sanand facility will focus on the high-volume manufacturing of vision camera systems for original equipment manufacturers (OEMs) in India. These components are engineered to support autonomous and semi-autonomous driving functions through Advanced Driver Assistance Systems (ADAS) and Advanced Rider Assistance Systems (ARAS).

While hardware manufacturing is centred in Sanand, the software and intelligence for these sensors are developed at Valeo’s research and development hub in Chennai. The facility is also scheduled to expand into the production of automotive displays and telematics control units to provide solutions for digital cockpits and connected vehicles.

The expansion is part of Valeo’s ‘Elevate 2028’ strategic plan, which identifies India as a priority market. By localising the production of vision systems, the company aims to streamline its supply chain and increase the delivery speed of safety technologies to regional partners. The investment is intended to transition the Sanand site into a multi-technology hub for automotive electronics.

Marc Vrecko, CEO, Valeo’s Brain Division, said, “The inauguration of this new camera line at our Sanand facility is a proud moment for our team and a proof to our dedication to the Indian market. By localising the production of these highly complex, advanced vision systems, we are not only streamlining our supply chain but also accelerating the delivery of world-class safety technologies to our partners."

Jayakumar G, Group President & Managing Director, Valeo India, added, “We are scaling our product portfolio in Sanand, India. This investment in a state-of-the-art surround-view camera line underscores our commitment to localizing high-tech solutions. It strengthens our ADAS manufacturing capabilities and R&D and ensures we continue to meet our customers’ evolving needs.”

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Belgian technology firm Magnax, which is working on yokeless axial flux electric motors, has secured around EUR 35.5 million investment from Pan-International Industrial Corp, in collaboration with Foxconn Group and members of an incoming management team.

The capital increase, conducted in two stages, has received foreign direct investment (FDI) approval and will result in Pan-International becoming the largest shareholder in Magnax.

Founded in 2015, Magnax develops yokeless axial flux electric motors for sectors including robotics, aerospace and electric vehicles. It also operates Traxial, a subsidiary focused on e-mobility.

The new CAPEX will be used towards industrialising the axial flux motor portfolio for high-volume deployment. Leveraging Foxconn Group’s manufacturing infrastructure and global supply chain. Research and development will remain in Belgium, while mass production will be located in China.

Axial flux motors differ from conventional radial flux machines by offering higher torque density and efficiency. These characteristics allow for reductions in vehicle weight and material usage. The architecture is intended for use in direct-drive industrial drives, machine automation and AI infrastructure, such as data centre thermal management.

As part of the transaction, Magnax has appointed a new CEO with experience in global industrial technology. The incoming management team is also co-investing in the company.

Kester Goh, Co-Founder, Magnax, said, “The capital will primarily be used to industrialise Magnax’s axial flux motor portfolio and support high-volume production. This partnership bridges European motor innovation with Asia’s largest advanced manufacturing ecosystem.”

Peter Leijnen, Co-Founder, Magnax, added, “Axial flux motors have a fundamentally better value proposition in several high-performance use cases. Their high torque density and efficiency enable customers to reduce weight and size of their end products. Lower material usage and higher efficiency translate directly into lower system cost and reduced carbon emissions.”

Daan Moreels, Co-Founder, Magnax, stated, “This is a new and important phase for Magnax. With Foxconn’s manufacturing scale and industrial ecosystem, Magnax gains the operational foundation required to deploy axial flux motor technology across global markets. The partnership accelerates the company’s transition from engineering innovation to large-scale industrial deployment.”

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