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 Automotive Research Association of India (ARAI) and COEP Technological University have signed a Letter of Intent to establish the Advanced Ergonomics and Human Factors Research Centre (AEHFRC) at COEP Tech’s Research and Innovation Park in Chikhali, Pune.

The initiative involves a planned investment of INR 1.05 billion and will function as a national facility focused on developing technologies tailored to the physical metrics of Indian users.

The facility will span approximately 38,000 square feet. The project will be executed in two phases: the first phase, spanning two to three years, will set up laboratories for posture evaluation, seating comfort analysis, human biomechanics and field of vision assessments; the second phase, over four to five years, will complete the full-scale deployment of the centre.

The centre will address sectors including automotive, defence, aerospace, railways, agriculture, industrial equipment, consumer goods and textiles. Key operational objectives include generating Indian anthropometric databases, establishing ergonomics standards, creating usability frameworks and offering training and certification programs.

The partnership will pursue research projects, consultancy assignments, and funding from government bodies, industry partners, and CSR initiatives to translate academic research into industrial applications.

Dr Reji Mathai, Director, ARAI, said, "As technology becomes increasingly human-centric, ergonomics and human factors play a critical role in ensuring safety, usability, and user well-being. Through this partnership with COEP Technological University, ARAI aims to create a national ecosystem that advances research, develops indigenous capabilities, and supports industry in creating products and systems that are better suited to Indian users and operating conditions. We believe the AEHFRC will play a significant role in strengthening India’s capabilities in human-centred design and innovation."

Prof. Sunil Bhirud, Vice-Chancellor of COEP Technological University, said: "COEP Technological University has consistently worked to translate research into societal impact. The proposed AEHFRC, in collaboration with ARAI, will provide a unique platform for interdisciplinary research, innovation, and industry engagement in ergonomics and human factors. We are confident that this initiative will contribute significantly to the development of Indian standards, indigenous technologies, and a skilled workforce capable of addressing national and global challenges."

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MathWorks and MapmyIndia Mappls have announced a collaboration to support automotive engineering teams developing and validating Advanced Driver Assistance Systems (ADAS) for Indian driving environments.

Under the partnership, MapmyIndia’s high-definition (HD) digital maps have been integrated with MathWorks' software ecosystem, including MATLAB, Simulink and RoadRunner.

The integration enables engineers to construct digital twins of Indian road infrastructure to simulate traffic scenarios and evaluate ADAS controllers within a Model-Based Design framework before physical vehicle testing.

MapmyIndia’s HD maps capture lane-level geometry, traffic controls and localised road features, including speed breakers, potholes and worn lane markings. The dataset addresses engineering challenges associated with Indian traffic environments, such as high-density traffic, variable lane discipline and evolving road layouts.

The combined software workflow links location intelligence data directly into algorithm development and system validation tools, aiming to reduce virtual testing cycles for original equipment manufacturers and tier-one automotive suppliers operating in India.

Sapna Ahuja, President of Automotive Business and Chief Operating Officer, MapmyIndia Mappls, said, "India's roads present some of the world's most complex and dynamic driving environments. Developing ADAS solutions for these conditions requires far more than adapting models built for structured traffic ecosystems. MapmyIndia's HD maps capture the scale and complexity of Indian roads with accuracy and detail — from lane-level geometry and traffic controls to speed breakers, potholes, faded lane markings and other critical localised road attributes. Our collaboration with MathWorks empowers automotive engineers to simulate real Indian driving conditions, validate systems earlier, and accelerate the development of ADAS solutions that are truly built for India."

Vijayalayan R, Senior Manager – Automotive, MathWorks, said, "As automotive teams expand ADAS development for India, virtual validation is becoming essential to evaluate system performance across diverse driving conditions. By integrating MapmyIndia’s HD maps with MATLAB, Simulink, and RoadRunner, engineers can test ADAS algorithms earlier in development, reduce reliance on costly physical testing, and improve system performance before deployment on Indian roads."

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Taiwan-headquartered Delta Electronics has announced a collaboration with NVIDIA aimed at developing autonomous driving systems for next-generation vehicles.

The partnership combines Delta’s automotive energy management, electric powertrain systems and in-vehicle high-performance computing system integration with the NVIDIA Hyperion reference platform and NVIDIA Halos safety system.

NVIDIA Hyperion serves as a sensor and compute architecture for Level 4 autonomous vehicles and robotaxis, utilising dual NVIDIA DRIVE AGX Thor processors to enable production-ready vehicle autonomy.

James Tang, Executive Vice-President of Mobility Business Category, Delta, said, "Autonomous driving requires years of technology development, continuous innovation, and strong system integration. Our commitment to the EV sector began several years ago, developing strong expertise in power electronics and key automotive technologies, and accumulating extensive development experience with world-class automakers. We are honoured that NVIDIA recognises Delta’s automotive expertise and strategic direction. Through this joint endeavour, we will further integrate AI and HPC capabilities into the enhancement of advanced autonomous driving functions, turning next-generation smart vehicles into real-world applications while pursuing new opportunities in the fast-growing smart mobility market."

Rishi Dhall, Vice-President of Automotive, NVIDIA, said, "Level 4 autonomous driving requires powerful in-vehicle computing, a comprehensive sensor architecture and close collaboration across the automotive ecosystem. By combining Delta’s automotive and system integration expertise with NVIDIA Hyperion, we can accelerate the development of safe, intelligent and scalable autonomous driving systems for the next generation of mobility."

Under the agreement, Delta will work alongside NVIDIA’s engineering teams to integrate its system technology into the Hyperion architecture, while leveraging NVIDIA's international network to broaden commercial engagement with global automotive manufacturers.

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Stellantis and Wayve will participate in the Wave by Vento event in Turin from 7 to 9 October 2026, featuring executive sessions, technical presentations and demonstration rides focused on artificial intelligence in mobility.

A keynote session titled ‘Technology Made for Humans’ will feature Stellantis CEO Antonio Filosa and Wayve Co-Founder and CEO Alex Kendall on 9 October. Moderated by Adam Jonas, global embodied AI and robotics strategist at Morgan Stanley, the discussion will focus on AI-powered mobility and strategic partnerships for technology deployment at scale.

During the event, Stellantis and Wayve will conduct demonstration rides in Fiat 500e and Maserati Grecale development vehicles equipped with the STLA AutoDrive platform powered by Wayve.

The system integrates the Wayve AI Driver to demonstrate hands-free, door-to-door supervised automated driving, categorised as Level 2++, in real-world driving conditions. The integration follows the Jeep Grand Cherokee development vehicle displayed at Stellantis' Investor Day in May, applying the same core AI driving software across three vehicle architectures without model-specific software re-engineering.

Announced in May 2026, the strategic partnership between Stellantis and Wayve focuses on supervised automated driving software for highway and urban environments. Stellantis targets its first commercial product launch using the technology in North America in 2028.

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