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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Toyota Kirloskar Motor (TKM) has signed a Memorandum of Understanding (MoU) with Wipro 3D to create a Centre of Excellence (CoE) for additive manufacturing. The facility will be located at the Toyota Technical Training Institute (TTTI) in Bidadi, Bengaluru. The partnership is intended to facilitate skill development and the integration of 3D printing technologies into production environments.

The centre will provide students with exposure to industrial applications of additive manufacturing, including rapid prototyping and the development of production aids. Wipro 3D will provide technical expertise and training modules covering internships, apprenticeships and workshops. The curriculum will also incorporate digital manufacturing and resource optimisation as part of an emphasis on Industry 4.0 technologies.

By leveraging these manufacturing capabilities, the initiative aims to reduce lead times and improve assembly line efficiency. The TTTI, which focuses on vocational education in trades such as mechatronics and welding, doubled its intake to 2,400 students in 2023. This collaboration aligns with the institution's objective to build technical talent for the automotive sector.

G Shankara, Chief Strategy Officer, Toyota Kirloskar Motor, said, "Our Human Resource Development philosophy at TKM follows core principles of Toyota such as, Continue the Quest for Improvement, Show Respect for People, under which we thrive hard to develop individuals in the Latest Technology of the New Age Era of automotive field. We are also committed to nurturing skilled talent and strengthening India’s manufacturing ecosystem. This collaboration will play an imperative role in nurturing future-ready talent, while contributing meaningfully to the Government’s Skill India Mission.”

Yathiraj Kasal, Business Head and General Manager, Wipro 3D, added, “This association reflects our commitment to strengthening India’s manufacturing ecosystem through capability building and innovation, while creating industry-relevant learning experiences.”

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TomTom has introduced Unified Speed Restrictions, a new service providing updated speed limit data for global regulatory compliance and Advanced Driver Assistance Systems (ADAS). The service is designed to help vehicle manufacturers exceed the minimum requirements of Intelligent Speed Assistance (ISA) regulations.

The service integrates multiple static and live data sources into a single output. By combining various inputs, the system provides continuous updates to vehicle software to ensure speed limit identification remains accurate across different driving environments.

Data sources utilised include:

• Unsigned speed limits: Based on regional road classifications.
• Roadside sign recognition: Camera-based detection of physical signs.
• Probe data: Aggregated information from connected vehicles.
• Variable speed limits: Real-time data from electronic overhead gantries.

Beyond safety compliance, the service supports automated driving functions by providing data for predictive path planning and smoother vehicle manoeuvres.

The solution is available as an API or pre-integrated within the TomTom ADAS SDK. The SDK is modular, allowing manufacturers and Tier 1 suppliers to incorporate the data into existing software stacks without vendor lock-in. This architecture is intended to reduce development costs and accelerate the deployment of predictive assistance features.

Manuela Locarno Ajayi, SVP of Product Engineering, TomTom, said, “Accurate and trusted speed information is foundational to road safety, regulatory compliance and automated driving at scale. With Unified Speed Restrictions, we are equipping automakers with a globally consistent, future‑ready foundation that reduces complexity, enabling higher levels of automation.”

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Detroit Engineered Products (DEP) has introduced DEP AIWorks, an engineering platform designed to integrate machine learning with physics-based simulation. The launch follows the conclusion of a five-city industry conclave held across Bengaluru, Delhi NCR, Hyderabad, Pune and Chennai.

DEP AIWorks is built as a physics-agnostic and tool-agnostic environment, allowing it to function across various datasets and engineering domains. The platform combines neural networks and physics-informed models with computer-aided engineering (CAE) solvers to provide predictive and generative capabilities within the product development lifecycle.

Core features of the platform include modular architecture, operational speed and ecosystem compatibility.

The platform is intended for use in the automotive, aerospace, energy, manufacturing and telecommunications sectors. It supports various stages of development, from early design exploration to manufacturing validation. By utilising data-driven learning alongside physics-based validation, the system aims to improve engineering productivity and accelerate decision-making cycles.

Radha Krishnan, President & Founder, DEP, said, “DEP AIWorks reflects the next step in how engineering organisations will adopt AI, not as a standalone tool, but as an integrated part of the product development lifecycle. By combining decades of simulation expertise with advances in AI, we are enabling teams to move faster while maintaining engineering rigor and reliability.”

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German tier 1 supplier ZF has introduced SolarBoost, a retrofittable solar panel system designed to support the 24-volt on-board electrical systems of city buses and coaches. The technology generates electricity during vehicle operation to recharge batteries, intended to reduce fuel consumption and maintenance requirements for fleet operators.

The system reduces the load on the drive engine by providing an alternative power source for on-board systems, which are traditionally supplied by the alternator. According to ZF, the additional energy can reduce fuel consumption by up to 3.5 percent, depending on weather conditions and application profiles.

The company states that key benefits for operators include battery longevity, as continuous recharging extends battery life. ZF reports potential savings equivalent to one battery per vehicle per year.

Furthermore, it enhances uptime by reduced requirement for stationary battery recharges and lower maintenance frequency. The system includes Bluetooth connectivity, allowing operators to track energy generation in real-time via a mobile application.

SolarBoost utilises a plug-and-play architecture designed for installation in an operator's own workshop using standard tools. The process does not require drilling into the vehicle structure or extensive rewiring, allowing for fleet-wide scaling with minimal disruption to service.

The hardware is engineered to withstand vibrations and weather conditions associated with heavy-duty transit. ZF provides a 5-year warranty and repair kits to support the long-term durability of the flexible panels.

The product is positioned as a scalable solution for bus operators to meet environmental targets. By utilizing renewable energy for electrical loads, the system assists in reducing the carbon footprint of intercity and urban transport fleets. It aligns with ZF’s broader strategy to deliver innovations that improve vehicle efficiency while supporting climate-friendly mobility.

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