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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Mobility engineering and technology company BlueBinaries has signed a definitive agreement to acquire the automotive testing business of Germany-based MicroNova AG.

The carved-out entity will operate as an independent company within the BlueBinaries group under the name NovaBinaries. Following the transaction, BlueBinaries projects annual revenue of USD 50 million and aims to expand revenue to USD 100 million in the coming years.

Founded in 2017 and headquartered in Chennai, BlueBinaries provides vehicle engineering, digital engineering, testing and homologation services to original equipment manufacturers across India, Europe, North America, the Middle East and Asia.

MicroNova, based in Vierkirchen near Munich, develops testing and validation systems for the automotive sector, including hardware-in-the-loop systems, test automation platforms, virtualisation solutions and engineering services. Its test automation platform, EXAM, is used by European automotive manufacturers. NovaBinaries will focus on software test solutions, hardware-in-the-loop systems, test automation, virtual validation, and software test factories by combining MicroNova’s product portfolio with BlueBinaries’ engineering operations.

Srinivas Aravapalli, Founder and CEO, BlueBinaries, said, "The acquisition of MicroNova’s industry-leading HiL Testing and Test Automation business represents a watershed moment in BlueBinaries’ journey towards absolute technological leadership in the global mobility ecosystem. By integrating these world-class validation and test automation technologies into our existing portfolio, we are uniquely positioned to offer an unmatched, end-to-end test offerings to our customers.”

Kishore LM, Founder and COO, BlueBinaries, said, “The acquisition of the Automotive Testing business from MicroNova is a strategic leap that enhances our ability to offer right technology solutions across automotive software testing. MicroNova’s technical depth, customer centricity, and regional strength align perfectly with our strategic vision to be the first partner choice for global customers complimenting our current portfolio. Our intent is to offer these proven technologies and better solutions globally combining precision, engineering excellence, scale, and flexibility while the mobility industry moves into the SDV and AI era.”

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A study conducted by Google and Kantar titled ‘Automobile Purchase Journey in the Age of AI’ shows that 93 percent of automobile shoppers in India utilise artificial intelligence (AI) interfaces during their research process.

The research indicates that the car buying process involves multiple digital platforms, with 87 percent of buyers interacting with Google services including Search, YouTube, Maps and Gemini. Consumers utilising artificial intelligence touchpoints consult an average of 7.8 resources to research and evaluate choices, compared to 6.9 touchpoints for buyers overall. Within Google Search, 90 percent of surveyed users reported encountering AI Overviews, while 89 per cent utilised AI Mode to process technical specifications, vehicle features and financing options. Furthermore, 80 percent of buyers using AI chatbots also turn to Google Search or YouTube for active research.

The findings highlight that initial consideration sets form early, with 80 percent of buyers maintaining a predefined list of brands prior to active research. Approximately six in 10 buyers use YouTube for casual exploration, where 77 percent of users rely on professional automotive reviewers to inform their choices. Daily media consumption habits among car buyers show that 63 percent watch YouTube, 55 percent stream YouTube on television screens, 54 percent read newspapers and 43 percent watch linear television. Decision-making remains a shared process within households, with 64 percent of respondents involving family members and 53 percent consulting spouses. Vehicle safety ratings and styling were identified as primary motivators by 41 percent of buyers.

Siddharth Shekhar, Director, Google India, said, "The car buying journey in India is deliberate, non-linear, and deeply digital-particularly ahead of the festive season, when consideration peaks. Buyers move between discovery on YouTube and conversational validation on Search. Among surveyed Google Search users, 90 percent come across AI Overviews and 89 percent use AI Mode to navigate nuanced, complex queries. As AI helps buyers navigate complex choices, our ad and commerce solutions help automotive brands respond to their intent-connecting initial curiosity directly to the showroom."

Virat Khullar, Head of Marketing, Hyundai Motor India, said, "The automotive purchase journey is increasingly shaped by moments of discovery, research and intent across digital channels. Our partnership with Google helped us harness the scale of YouTube to build awareness and the intelligence of AI-powered Search ad solutions to identify and convert high-intent consumers. By unifying upper- and lower-funnel marketing, we were able to deliver a more relevant and efficient customer experience, turning consideration into action and driving strong sales momentum for Hyundai Verna."

The study was carried out by Kantar in May 2026 across metropolitan and Tier-1 cities in India, surveying 1,022 consumers who had purchased a car within the preceding six months.

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Accenture and Google Cloud have announced that Volvo Cars has signed on as the lead industry partner for Horizon, an open-source software development platform designed for car makers and automotive suppliers to build, test and deploy software on the Android Automotive Operating System.

The Horizon platform unifies cloud-native development tools, virtual testing environments and artificial intelligence workflows. Volvo Cars is migrating its global software development environment for the Android Automotive Operating System to the platform to accelerate engineering processes and virtual testing across its global development teams.

Insights gathered from Volvo Cars' deployment will be used by Accenture and Google Cloud to refine the platform and expand its generative artificial intelligence features for automotive and industrial manufacturers.

According to metrics provided by Accenture and Google Cloud, testing speeds using virtual Cuttlefish-based Android Automotive environments can improve by up to 9 times, while infotainment feature development costs can decrease by up to 40 percent. Software build times, which previously required up to two hours, can yield feedback within minutes through caching and build pipeline optimisation.

Remote access to virtual and physical device farms allows engineers to test software without requiring local physical test equipment, while virtual workbenches enable developers to set up development environments in seconds.

Gregor Zetsche, Head of Connected Experience, Volvo Cars, said, "We’re building some of the most complex products in the world, which requires a development environment built to match. As Horizon’s lead industry partner, we can directly solve our toughest engineering challenges and empower our teams to deliver new experiences faster than ever."

Juergen Reers, Global Automotive & Mobility Lead, Accenture, said, "Horizon enables a faster, more flexible and efficient way to deliver software-defined vehicle features. Its standardised, repeatable and scalable processes help deliver reliable, high-quality software products, while significantly reducing time to market. Horizon will allow Volvo Cars’ engineers to focus on what matters most: creating differentiated vehicle experiences and continuously delivering new value to drivers through software at high speed."

Henry Bzeih, Global Director for the Automotive Industry, Google Cloud, said, "Software now defines the automotive brand. Horizon on Google Cloud gives Volvo Cars the ability to move faster while releasing high-quality software and features on a cadence that matches the expectations of modern mobility. This is how next generation digital experiences reach drivers at agile speed."

Accenture and Google Cloud are working with additional automotive and industrial organisations to expand adoption of the Horizon platform across international markets.

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Emerson has announced the expansion of its test and measurement research and development (R&D) facility in Bengaluru, which it claims is an additional 50 percent.

The investment increases capacity at the site to develop software-defined and automated validation technologies for industrial customers.

The Bengaluru facility operates as Emerson's NI Software Centre of Excellence and represents the company's second-largest test and measurement R&D centre globally. Engineering teams at the site hold product responsibility for test software platforms, AI-enabled engineering capabilities, systems engineering technologies and radio frequency test software. The tools serve clients across the semiconductor, aerospace, defence, transportation, life sciences and manufacturing sectors.

Ritu Favre, President of Emerson's Test & Measurement business, said, "Bangalore plays an increasingly strategic role in Emerson’s global test innovation network. The site combines deep expertise in test software and AI-enabled engineering and validation technologies with close connections to rapidly evolving industries. This investment helps customers manage growing product complexity, streamline validation and bring new innovations to market faster."

The expansion provides capacity to advance automated validation workflows and integrated test platforms as hardware complexity increases across shortened product development timelines.

Emerson's investment aligns with domestic growth in semiconductors, electric mobility, and aerospace manufacturing driven by initiatives such as the India Semiconductor Mission and the National Electric Mobility Mission Plan.

Alongside the R&D centre, Emerson operates a second Bengaluru location dedicated to application engineering, calibration services, sales and customer support.

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