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

Comments (0)

ADD COMMENT

Link Copied!

German technology company Elektrobit is set to showcase innovations focused on creating the ‘right-sized’ software-defined vehicle (SDV) at CES 2026 in Las Vegas. The company will address the industry challenge of balancing innovation, scalability and affordability as vehicle complexity and development costs rise.

The demonstrations, located at the Las Vegas Convention Center, West Hall, will provide insights into strategies for reducing SDV development complexity and accelerating the process of bringing next-generation vehicles to market.

Elektrobit will feature several technologies designed to streamline SDV creation and performance:

• Linux for Safety Systems: The EB corbos Linux for Safety Applications will be demonstrated with a safety-certifiable cockpit by Telechips. This exhibit shows how open-source innovation and functional safety can be combined for real-time performance in Advanced Driver-Assistance Systems (ADAS).
• Automated Integration: A platform highlighting API-based extensions across Continuous Integration/Continuous Delivery/Continuous Testing (CI/CD/CT) workflows. It uses intelligent tooling, including AI-assisted automation, to automate configuration, scripting and test case creation for faster, higher-quality software delivery.
• SDV Cockpit Solutions: Solutions range from virtual low-code design tools to a modular, safety-certified automotive Operating System (OS) and ready-to-integrate hardware platforms, all designed to accelerate the creation of vehicle experiences.
• Smart EV Platform: A modular software and hardware platform co-developed with Foxconn aims to bring SDVs to market faster and more cost-effectively. It delivers the core vehicle control units and software platform without supplier lock-in.

Maria Anhalt, CEO of Elektrobit, will participate in the CES 2026 conference program. She is scheduled to speak on the Smart Rides panel on 8 January 2026.

The panel, which includes participants from Magna International and TomTom, will cover how SDVs are transforming safety and personalisation, using data to protect drivers and deliver tailored driving experiences.

Key members of the Elektrobit executive team, including Chief Commercial Officer Christoph Herzig and Head of Strategic Business Development Dr. Siegfried Dirr, will also attend the event.

Comments (0)

ADD COMMENT

Link Copied!

Star Engineers India and ConnectM Technology Solutions have formed a joint venture, StarConnectM, to design, develop, manufacture and scale intelligent connected vehicle products for Automotive OEMs. The new entity aims to bridge the gap between software innovation and large-scale automotive production.

The partnership will combine Star Engineers’ manufacturing excellence, process reliability and quality assurance with ConnectM’s Smart Vehicle Electronics and Intelligent Mobility Solutions.  

StarConnectM’s focus includes connected vehicle architecture, software-defined vehicle platforms and next-generation mobility electronics.

The joint venture offers an end-to-end capability for OEMs from concept to production, integrating IoT intelligence, embedded electronics & software and scalable manufacturing.

Divya Ramraika, Managing Director, Star Engineers, said, “StarConnectM marks a milestone in our journey toward intelligent mobility. With ConnectM’s technology and Star’s manufacturing strength, we are creating scalable, reliable and connected solutions that redefine the end-user experience.”

Girish Subramanya, Managing Director, ConnectM, said, “This joint venture eliminates the traditional gap between innovation and manufacturing. Automotive OEMs today need partners who can deliver technology architectures for connected, software-defined vehicles and also scale them seamlessly into production.  StarConnectM stands exactly at that intersection, creating an ecosystem where technology and manufacturing co-exist as one integrated value chain.”

The JV will initially focus on the Indian market, with a roadmap for select global market expansion.

Comments (0)

ADD COMMENT

Link Copied!

Kinetic Green Energy and Power Solutions and Exponent Energy have formed a strategic alliance to launch 15-minute rapid charging solution for electric three-wheelers (e-3W), covering both the L5 and L3 categories.

This solution targets e-rickshaws and e-cargo carts, aiming to improve operational efficiency for last-mile mobility operators.

The partnership will see integration of Exponent Energy’s proprietary full-stack platform — which includes battery technology, a charging network and intelligent software—enabled Kinetic Green vehicles to achieve a 15-minute full charge.

This rapid charging is expected to extend daily operating hours by up to 30 percent. As per the understanding, Kinetic Green’s popular L3 models, including the Safar Smart, Safar Shakti, and Super DX will now feature this rapid charging technology.

The L5N Safar Jumbo loader and the upcoming L5M passenger variant will also utilise the 15-minute charging to allow for faster turnaround times, translating to more trips and higher earnings for operators.

The joint solution is backed by an industry-leading 3,000-cycle warranty. The digital platform will also provide features such as real-time state of charge tracking and predictive maintenance alerts.

To support Kinetic Green customers, Exponent Energy’s existing network of over 160 charging stations across four cities will be made available to the e-3W fleet. The infrastructure is planned to expand rapidly into major metros and tier II, III cities over the next 12 months.

Dr. Sulajja Firodia Motwani, Founder and CEO, Kinetic Green, said, “This partnership marks a defining moment for India’s electric three-wheeler sector. By bringing the country’s first 15-minute full charge solution to e rickshaws and cargo carts – the backbone of India’s urban last mile mobility - we are empowering owner operators, small & large fleet operators to achieve unprecedented uptime and efficiency. Our customer-centric approach drove this exclusive strategic partnership for our L3 e3W category offer our customers the best cost of ownership. This partnership accelerates our mission to democratise green mobility, making sustainable transportation accessible and affordable for all while propelling the development of India's EV infrastructure.”

Arun Vinayak, CEO and Co-Founder of Exponent Energy, said, “At Exponent Energy, our mission is to make EVs the easiest choice – and that means solving real problems for real operators. This collaboration allows us to embed our rapid charging platform into the entire portfolio of e3Ws in India – spanning both L5 and L3 segment – delivering unparalleled speed, reliability and scalability to operators and creating a blueprint for the future of electric transport.”

Comments (0)

ADD COMMENT

Link Copied!

BorgWarner is significantly expanding its partnership with Great Wall Motor by securing two new electrified propulsion projects, building upon two previously announced dual inverter programmes. These new initiatives are scheduled to enter mass production in 2026. A cornerstone of this collaboration is BorgWarner's advanced dual inverter technology, which utilises a highly integrated design. This single unit can simultaneously control and drive two motors, offering superior packaging flexibility and easier installation for vehicle manufacturers.

The technology's sophistication is underscored by its use of a power module with double-sided cooling and the latest Viper power switches. This configuration can reduce thermal resistance by as much as 50 percent compared to conventional single-sided cooling, leading to a substantial increase in power density. Furthermore, the design allows different semiconductor dies to be packaged within identically sized modules, ensuring compliance with China's stringent CLTC efficiency standards. The system also incorporates adaptive battery voltage regulation, which broadens the motor's high-efficiency operating range to improve overall performance.

Emphasising flexibility, BorgWarner employs a platform-based design that adapts to various hybrid vehicle architectures. For the newly awarded projects, the HEV version of the dual inverter integrates a DC/DC converter and offers an optional voltage boost module. In contrast, the PHEV variant is designed without these components. This modular strategy provides manufacturers with critical adaptability, enabling faster product development cycles while simultaneously reducing both design and production costs.

Dr Stefan Demmerle, Vice President of BorgWarner Inc. and President and General Manager, PowerDrive Systems, said, “BorgWarner’s technical expertise in electrification and dual inverter products has earned Great Wall Motor’s continued confidence. The extension of this collaboration not only reflects recognition of our products and technologies but also underscores our strong commitment to supporting our customers’ new energy strategies. We will remain dedicated to accelerating their electrified vehicle portfolio.”

Comments (0)

ADD COMMENT

Link Copied!