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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Changan Automobile and CATL have unveiled the first mass-production passenger vehicle equipped with sodium-ion batteries. The vehicle, showcased at the 'Changan SDA Intelligence Milestone Release', is scheduled for market release by mid-2026. CATL, acting as the strategic partner for the project, will supply its Naxtra sodium-ion batteries across Changan’s brands, including Avatr, Deepal, Qiyuan and UNI. The partnership introduces a dual-chemistry approach to the market, utilising sodium-ion alongside lithium-ion technologies.

CATL's Naxtra battery reaches an energy density of 175 Wh/kg. Utilising a Cell-to-Pack system and a battery management system (BMS), the technology provides a range exceeding 400 km. Future iterations are projected to reach 500–600 km for battery electric vehicles (BEVs) and 300–400 km for hybrids.

The technology is designed for operation in cold climates. At –30deg Celsius, the battery delivers triple the discharge power of lithium iron phosphate (LFP) alternatives. It maintains 90 percent capacity retention at –40deg Celsius and continues to function at –50deg Celsius. Safety testing, including drilling and crushing, resulted in no smoke or fire.

The global sodium-ion battery market is forecast to grow from USD 1.39 billion in 2025 to USD 6.83 billion by 2034. To support adoption, CATL plans to establish over 3,000 Choco-Swap battery swap stations across 140 cities in China by the end of 2026, with a focus on northern regions.

The launch follows a decade of research. Since 2016, CATL has invested nearly 10 billion RMB (USD 1.45 billion) into sodium-ion technology, developing approximately 300,000 test cells. The project was supported by a dedicated team of 300 personnel to ensure scalability and performance.

Gao Huan, CTO of CATL's China E-car Business, said, "The arrival of sodium-ion technology marks the beginning of a dual-chemistry era. Changan's vision shows both its responsibility for energy security and its strategic foresight. Much as it embraced electric vehicles years ago, Changan is once again taking the lead with its sodium-ion roadmap. At CATL, we value the opportunity to work alongside such an industry leader and fully support its strategy, combining our expertise to bring safe, reliable and high-performance sodium-ion technology to market."

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Following its international unveiling at CES 2026, drivebuddyAI, a leading innovator in AI-powered Advanced Driver Assistance Systems (ADAS) and Driver Monitoring Systems (DMS), recently demonstrated its technology at the ARAI ADAS Test City. The company presented its range of vision-based Advanced Driver Assistance and Driver Monitoring Systems, focusing on their reliability in the varied and challenging conditions typical of Indian roads.

Live demonstrations were conducted using a heavy commercial vehicle to showcase the platform's versatility in meeting various compliance standards. A single, integrated hardware and software setup, utilising a fused network of cameras for 360-degree perception, executed multiple test scenarios simultaneously. These included a driver monitoring system that detects drowsiness, distraction and seatbelt usage in line with both Indian and European regulations. Further tests illustrated the vehicle's ability to warn of pedestrians moving into its path, identify potential collisions with cyclists in blind spots and issue forward collision warnings by combining radar and camera data.

Beyond merely fulfilling test requirements, the demonstrations highlighted practical applications that extend into everyday driving situations. This focus on real-world functionality is backed by extensive validation, with the company's systems having analysed nearly four billion kilometres of driving data. This has reportedly led to significant safety improvements, including a marked decrease in incidents caused by driver fatigue and a substantial reduction in overall fleet risks.

Currently validated for commercial vehicles against India's AIS-184 standard and Europe's stringent General Safety Regulation and Euro NCAP protocols for 2026, the technology is also adaptable for passenger cars. This scalability offers automotive manufacturers and their suppliers a pathway to not only meet but surpass upcoming global safety mandates. By refining its AI through extensive fleet operations over billions of kilometres before adapting it for original equipment manufacturer compliance, drivebuddyAI aims to deliver a mature, rigorously tested product that ensures an enhanced user experience.

Nisarg Pandya, CEO and Founder, drivebuddyAI, said, “ADAS Test City from ARAI is a great initiative, and we value participating in a format where we can showcase live demonstrations to a large audience together on the vehicle. This time, the turnout was significant and provided a strong opportunity to establish drivebuddyAI as one of the key players in the upcoming OEM compliance requirements. The engagement and response we received were phenomenal, reinforcing both the market need and the industry’s confidence in our solutions. The upcoming ADAS-compliant vehicles must have technology that works in Indian scenarios to achieve meaningful safety improvements and reduce fatalities.”

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Bharat Forge and VVDN Technologies have signed a Memorandum of Understanding (MoU) to explore collaboration across the automotive, defence and data centre sectors. The agreement establishes a framework for the joint development of products, including AI server platforms and autonomous systems.

The partnership combines VVDN’s capabilities in electronics design, software and system integration with Bharat Forge’s experience in manufacturing and precision engineering.

The companies intend to target opportunities in next-generation technologies. Key areas of focus under the MoU include development of systems for vehicle platforms, engineering solutions for defence applications and design & manufacturing of AI server platforms to support generative intelligence and sustainable computing.

The collaboration is designed to create a framework for knowledge exchange and operational efficiency, allowing both entities to address the requirements of the global AI ecosystem.

Amit Kalyani, Vice-Chairman & Joint MD of Bharat Forge, said, “This partnership enables us to leverage advanced technologies, accelerate innovation, and enhance the quality of solutions we deliver to our clients and stakeholders. By aligning with partners who share our vision for excellence, we create a robust ecosystem that fosters knowledge exchange, operational efficiency, and long-term value creation. Such alliances are integral to our strategy, ensuring that we remain competitive, future-ready, and capable of addressing the evolving needs of the markets we serve.”

Puneet Agarwal, CEO, VVDN, said, “This partnership with Bharat Forge aligns with our vision of driving innovation through advanced engineering and digital technologies. By combining our product engineering and manufacturing strengths with Bharat Forges domain leadership, we aim to accelerate the development of next-generation solutions across automotive, defence and data centre ecosystems, amongst other next-gen technologies.”

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Catena-X Automotive Network, a non-commercial organisation, has identified three shifts in data exchange that are expected to define the global automotive industry in 2026. The association reports that data collaboration is becoming a board-level priority and a prerequisite for trade as eight of the world’s top ten suppliers join the ecosystem.

The association brings together a coalition of OEMs, suppliers, technology providers, and industry bodies, including ADAC, AIAG, BMW, Mercedes-Benz, Porsche, Renault, Volkswagen Group companies, Volvo, VDA, TÜV SÜD, Fraunhofer, Amazon Web Services, Huawei, Microsoft and Magna, among others.

Catena-X suggests that data fragmentation is becoming a trade barrier. Regulations such as the Carbon Border Adjustment Mechanism (CBAM) and the EU Digital Battery Passport increase the requirement for product-level evidence. Failure to produce consistent data can result in market exclusion or increased costs.

The association provides standards designed to make documentation reusable across partners. This approach aims to prevent the need for bespoke integrations for every customer, particularly for Tier 2 and Tier 3 suppliers where data readiness varies.

Data management is increasingly competing with R&D and intellectual property for budget allocation. Catena-X warns that compliance costs can rise from 0.05 percent to 2 percent of revenue if reporting remains manual and duplicated.

To address this, the network utilises toolkits such as the Product Carbon Footprint (PCF) framework. Standardised inputs allow sustainability data to be shared across companies, which the association claims is up to five times more efficient than legacy reporting methods.

Software Traceability and Cybersecurity

In 2026, software risks are expected to become a primary trigger for vehicle recalls. As vehicles become software-defined, the ability to trace code lineage and component provenance is necessary for risk management.

Catena-X highlights the Software Bill of Materials (SBOM) as a tool for triage during cyber incidents. Making software versions and dependencies visible across tiers allows for faster responses to security vulnerabilities.

Hanno Focken, Managing Director, Catena-X, said, “We are seeing a major shift in what the industry is being asked to prove. Data is becoming a condition of trade and a real cost-to-serve. At the same time, cyber incidents are increasingly becoming a product recall risk. Work that used to sit in the background is now affecting market access and margins. Catena-X exists to make trusted interoperable exchange practical across every tier of the supply chain, while protecting data sovereignty.”

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