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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Nexteer Automotive has announced that its Electro-Mechanical Brake (EMB) is ready for mass production following extensive development and validation. First introduced as a concept at Auto Shanghai 2025, the EMB completes Nexteer’s Motion-by-Wire portfolio, allowing the company to offer integrated steer-by-wire and brake-by-wire solutions.

The EMB system has undergone a year of rigorous testing, including simulations, bench tests and extreme winter performance validation. According to the company, more than 20 original equipment manufacturers (OEMs) have tested the product, with several projects now moving into technical co-development.

Nexteer is leveraging its historical expertise in steering to create a unified chassis control ecosystem. This approach offers several advantages for modern vehicle architectures:

• Software-Defined Safety: Nexteer’s ‘braking-steering fusion’ software provides cross-domain redundancy, a critical requirement for Level 3 and higher autonomous driving. The software features open interfaces for rapid integration into OEM-specific architectures.
• Hardware Efficiency: By platformising actuator modules – including motors, sensors, and ASIL-D microcontrollers – Nexteer is reusing hardware components across steering and braking systems to reduce costs and development timelines.
• Global Supply Chain: The company is utilising high supplier overlap between its steering and braking divisions to achieve economies of scale through centralised procurement.

Jun Li, Senior Vice-President and APAC Division President, Nexteer Automotive, said, “The integration of Nexteer’s Steer-by-Wire and EMB isn’t just a simple ‘1+1’ — it’s a natural evolution rooted in the fundamentals of mechatronics, and a key enabler for achieving both safety and cost-effectiveness in high-level autonomous driving. Choosing Nexteer means more than just picking up two components — it means getting a complete, proven, production-ready, and cost-effective chassis motion control solution.”

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Technology firm AUMOVIO and adhesive manufacturer tesa have entered a partnership to introduce a new mechanical integration solution for automotive displays.

The collaboration focuses on a robotic bonding process that allows for debonding-on-demand, a feature designed to facilitate repairs and recycling throughout a vehicle's life cycle.

The system utilises a 2 mm wide adhesive tape that is applied robotically, providing an immediate load-bearing bond without curing time. This narrow profile enables the manufacturing of ultra-thin display bezels similar to those found in smartphones.

Unlike traditional permanent adhesives, this bond can be selectively detached with minimal effort, allowing individual display components to be replaced or reworked during production or service without discarding the entire module.

The technology is engineered to compensate for material expansion across automotive temperature ranges while supporting circular economy principles. By enabling the recovery of valuable components at the end of a vehicle's service life, the solution aligns with AUMOVIO’s sustainability strategy. The partners are currently preparing to integrate this process into volume production during the second quarter of 2026.

Pavel Prouza, Head of the User Experience (UX) Business Area at AUMOVIO, said, “The combination of highly precise, automated application and targeted detachability adds an important element to our manufacturing and quality processes. It strengthens the robustness of our production, reduces material waste, and promotes efficient use of valuable components. For the end customer, this could even mean that future repairs may require replacing only the affected individual components in a cost-effective way.”

David Caro, Head of Automotive, tesa, said, “This partnership demonstrates how innovative materials technology is advancing the mobility of tomorrow. Together with AUMOVIO, we offer automated adhesive bonds that not only provide long-term durability but can also be deliberately debonded – enabling efficient production, longer product life cycles, and circular product concepts. This helps our customers translate their sustainability goals into tangible product solutions.”

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China’s WeRide has announced that at the Wuhu round of the Second China Urban Intelligent Driving Competition, the Chery Exeed Sterra ET, powered by the WeRide WRD 3.0 (jointly developed with Bosch), claimed first place with a lead of over 10 points.

As the first publicly traded Robotaxi company, WeRide operates in over 40 cities across 12 countries. It holds autonomous driving permits in eight major markets, including the UAE, Singapore and the US, providing L2 to L4 solutions across the mobility, logistics and sanitation sectors.

This win marks the first time in the competition's history that a single solution has achieved four consecutive championships, following previous victories in Taizhou, Wenzhou and Jinhua.

The WRD 3.0 system utilises a one-stage end-to-end ADAS solution designed to handle complex urban environments. Its performance is driven by two key internal technologies:

• GENESIS Simulation World Model: A proprietary platform that uses generative AI to reproduce rare ‘long-tail’ scenarios, bridging the gap between virtual training and real-world application.
• L4 Driverless Data Integration: The system leverages large-scale data from WeRide's fully driverless operations to refine perception and planning in dense traffic, such as street markets and mixed-use urban roads.

WeRide has transitioned WRD 3.0 from an algorithmic concept to a production-ready system, achieving hardware-software decoupling that allows it to run on different computing tiers.

With the launch of the Aion N60, WeRide has become the first autonomous driving provider to achieve mass production of one-stage end-to-end technology on both Nvidia Drive and Qualcomm Snapdragon platforms.

While strengthening its presence in China with brands like GAC Trumpchi and Hyptec, WeRide is expanding its international footprint. Through partnerships with Tiggo, Omoda and JAECOO, the company aims to export its intelligent driving solutions to global markets.

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South Korea-based Stradvision, a company specialising in AI-based vision perception technology, has been selected by a global commercial vehicle manufacturer to deploy its SVNet software across its Indian vehicle lineup.

The programme focuses on fleet-scale deployment of Advanced Driver Assistance Systems (ADAS) in a market where perception software must balance technical reliability with cost-efficiency.

The company stated that the Indian commercial vehicle sector requires ADAS solutions capable of operating on resource-constrained hardware while maintaining performance in high-density traffic.

SVNet is engineered to detect and classify objects in mixed-traffic environments, including two-wheelers, three-wheelers and pedestrians. This software architecture allows the OEM to implement functions such as automatic emergency braking, forward collision warning and lane departure warning across various models using a single software stack.

The deployment is structured to allow the manufacturer to standardise its perception platform while adjusting for model-specific hardware.

Till date, Stradvision has deployed approximately 5 million units of SVNet globally, providing the production maturity required for high-volume commercial vehicle programmes. This project indicates a shift in the automotive industry towards perception solutions that prioritises scalability and operational efficiency across diverse market conditions.

Philip Vidal, CBO, Stradvision, said, "India's commercial vehicle segment is one of the most consequential ADAS markets opening right now. The scale of the fleet, the complexity of the traffic environment, and the cost requirements make it a genuine test of whether perception software can perform where it matters most. SVNet was built for exactly this kind of deployment, and this program is a strong validation of that."

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