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!

HARMAN has partnered with Tata Motors Passenger Vehicles (TMPVL) to provide the in-cabin technology for the all-new Tata Sierra. The collaboration introduces 5G-ready connectivity and a multi-speaker audio system to the SUV, marking an expansion of the 12-year relationship between the two companies.

The vehicle features HARMAN Ready Connect, a suite of telematics control units (TCUs) manufactured at HARMAN’s facility in Pune. The system utilises a modular network access device architecture, allowing for a transition from 4G to 5G technology. It supports safety functions such as emergency calling, stolen-vehicle tracking and roadside assistance, alongside productivity features like video conferencing and high-definition streaming.

The interior includes a Horizon View Display and a digital instrument cluster powered by HARMAN’s infotainment architecture. The system supports gaming with joystick compatibility and features a Ready Link Marketplace, which allows users to download third-party Android applications.

For driver assistance, the Sierra incorporates a Surround View System (SVS) and 4sight Blind-Spot Monitoring. Navigation is provided through a native mapping solution from MapmyIndia. The cabin experience also includes ‘Relax Mode’ for sensory visuals and 'Silent Mode' to mute non-regulatory alerts.

The SUV introduces a 12-speaker JBL audio system, which includes an enclosed subwoofer and a soundbar. This configuration supports Dolby Atmos and represents a first for an Indian manufacturer. The integration of these components is intended to provide a multi-dimensional sound profile tailored to the vehicle's cabin.

By localising the production of the telematics hardware in India, HARMAN aims to provide TMPVL with greater supply-chain agility and shorter development cycles. The ‘Make-in-India’ initiative for Ready Connect ensures the technology is adapted to local driving conditions and consumer requirements.

Suman Sehra, VP, Portfolio Management, Connectivity at HARMAN International, said, “HARMAN Ready Connect represents the shift toward software-defined, experience-led mobility, and the new Tata Sierra is a perfect expression of that evolution. By collaborating closely with TMPV’s R&D team, we focused on value co-creation and delivered a platform that brings high-performance connectivity, scalable architecture, and future-ready digital services to support the connected digital life.”

Mohan Savarkar, Chief Product Officer, Tata Motors Passenger Vehicles, added, “With the Sierra, our focus was to create a cabin experience that feels as advanced and intuitive as the world our customers live in. Connectivity, digital interfaces and audio are no longer add-ons—they define how people engage with their vehicle every day. Our collaboration with HARMAN enables us to deliver a future-ready architecture, immersive in-cabin experiences and premium audio.”

Comments (0)

ADD COMMENT

Link Copied!

Sterling Tools has entered into a partnership with MINIEYE, a Hong Kong-listed developer of intelligent driving and in-cabin solutions. The collaboration focuses on the deployment of Advanced Driver Assistance Systems (ADAS) and Driver Monitoring Systems (DMS) tailored specifically for the Indian automotive market.

As per the agreement, Sterling Tools will lead application engineering and on-ground adaptation. This involves tuning perception algorithms to account for Indian road scenarios, traffic patterns, and environmental conditions. The project aims to ensure that safety technologies, such as Autonomous Emergency Braking (AEB) and Lane Departure Warning Systems (LDWS), function reliably in local settings rather than relying on global configurations.

The partnership is positioned to meet upcoming Indian safety mandates. Effective 1 January 2027, regulations will require the fitment of ADAS and Driver Drowsiness and Attention Warning Systems (DDAWS) in new vehicle models. The scope of the collaboration covers both commercial and passenger vehicles, including technologies for Forward Collision Warning (FCW) and Blind Spot Monitoring.

MINIEYE provides technology that complies with EU General Safety Regulations and holds Automotive SPICE V4.0 CL3 certification. Sterling Tools is supporting this transition as part of a broader expansion into electronics and safety-critical components, which includes electric vehicle power electronics and motor solutions.

Anish Agarwal, Director, Sterling Tools, said, “Road safety and regulatory compliance are becoming increasingly important across both commercial and passenger vehicle segments in India. This collaboration allows us to work with a global technology partner to address the growing need for driver assistance and monitoring systems that are engineered for Indian operating conditions. At Sterling Tools, our focus remains on supporting OEMs with engineered, safety critical technologies aligned with upcoming regulatory requirements.”

Dr Liu Guoqing, Founder and Chairman, MINIEYE, added, “Partnering with Sterling Tools marks a vital step in bringing intelligent driving to India, leveraging Sterling Tools local expertise to translate technology into production-ready applications that enhance vehicle safety.”

Comments (0)

ADD COMMENT

Link Copied!

Faraday Future Intelligent Electric Inc. has released technical details regarding the Front AI Communication Ecosystem (F.A.C.E.), a system featured on the electric version of its FX Super One MPV.

The technology replaces the traditional front grille with a display and an AI avatar designed to act as a co-pilot and communication interface.

The system utilises multimodal interaction, including voice, gesture and touch, to respond to user needs. It is controlled via a smartphone application, allowing for the display of custom graphics, logos and streaming video while the vehicle is stationary. The hardware incorporates sensors that enable the AI agent to perceive its surroundings and interact with individuals outside the vehicle.

The F.A.C.E. system uses a Large Language Model (LLM) reasoning layer to interpret user intent and execute actions. Its functionality includes role-awareness personalisation, which distinguishes between owners, family members and unknown persons to provide appropriate responses.

The system supports proactive communication, such as initiating responses when someone approaches the vehicle to improve safety. Users can also interact with the vehicle’s voice assistant from the exterior to check status or request access. The FX Super One platform is engineered to support both battery electric and AI hybrid extended range (AIHER) powertrains.

The FX Super One is positioned as a mass-market MPV for the United States. Faraday Future has established a three-stage delivery structure for the model:

• Phase One: Deliveries to FX Partners are expected to begin in the second quarter of this year.
• Phase Two: B2B partner deliveries and production ramp-up are scheduled for the third quarter.
• Phase Three: Full-scale consumer market deliveries are targeted for the final quarter of this year or the first quarter of 2027.

Max Ma, Global CEO, FX, said, “Offering technology like our unique F.A.C.E system in a new category of vehicle will be a game changer in the marketplace. It will allow users to connect with the world in a totally new way. It can express itself and communicate to the world in a way never seen before in a vehicle. The FX Super One is not just a new MPV, it is the first mass-market, first-class Embodied AI MPV designed for the U.S. market, where intelligent space, AI interaction, sensing, computing and power and extended-range capability come together in a single platform.”

Comments (0)

ADD COMMENT

Link Copied!

German component supplier Schaeffler is leading the ReDriveS research project, an initiative funded by the German Federal Ministry for Economic Affairs and Climate Action. The project, which includes 25 partners from industry and academia, aims to develop an automated and scalable recycling concept for electric axle drive systems.

The project has a volume of over EUR 25 million, with funding exceeding EUR 16 million over a 36-month period. The technical focus is on robot-guided disassembly to recover materials such as rare earths, copper, aluminium and steel. This approach is intended to support the repair of drives, the reuse of subcomponents, or the recycling of materials to meet statutory requirements and secure supply chains.

A central component of the project is the development of a digital twin that processes data throughout the lifecycle of an axle drive. This digital model assesses the condition and geometry of units to determine whether they should be dismantled into main components – such as the motor, inverter, or transmission – or broken down further for material recycling.

The system is designed to be manufacturer-independent, allowing the technology to be used as an industry solution for original equipment manufacturers (OEMs) and recyclers. The project also explores data-based business models for axle drives enabled by this digital ecosystem.

Prof. Dr. Tim Hosenfeldt, Head of Central Technologies at Schaeffler, said, “With ReDriveS, we are launching a key project for the circular economy in electric mobility as consortium leader, together with the German Federal Ministry for Economic Affairs and Energy and strong partners. Our goal is to make electric axle drives significantly more resource-efficient through digital twins, automated disassembly and high-quality recycling – thereby securing raw materials and supply chains, reducing CO2 emissions, and strengthening Germany as a location overall.”

Comments (0)

ADD COMMENT

Link Copied!