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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Geely Auto Group has announced the formation of Geely Technology Europe (Geely Tech Europe), a unified research and development centre integrating its engineering facilities in Gothenburg, Sweden and Frankfurt, Germany. The hub will serve as a strategic link to the Geely Research Institute (GRI) in China to develop vehicle platforms for international markets.

Geely Tech Europe aims to provide engineering support for the Zeekr, Lynk & Co and Geely brands. A primary operational goal is to reduce the time gap between Chinese and international product launches to less than 6 months. The organisation plans to double its managed European vehicle projects by 2027 to meet global sales targets.

The hub focuses on three technical pillars:

• Architecture Development: Co-creating mechanical and electronic/electrical (E/E) architectures.
• Market Optimisation: Integrating international regulatory requirements and customer needs into vehicle programmes.
• Digital Innovation: Developing software-defined vehicles using Agentic AI, advanced driver-assistance systems (ADAS) and smart cockpits while maintaining European data privacy standards.

The formation of Geely Tech Europe follows the evolution of China Euro Vehicle Technology (CEVT), established in 2013 and the subsequent Zeekr Technology Europe. The combined teams have previously developed the Compact Modular Architecture (CMA), used in over four million vehicles, and the SEA-S platform, which features a 900-volt high-voltage system.

Giovanni Lanfranchi, CEO, Geely Technology Europe, said, “Europe is more than a key market; it is a global benchmark for automotive excellence and demanding customer expectations. To succeed, it is essential to anticipate and incorporate the needs of all regions from the start of development. Establishing Geely Technology Europe creates a genuinely borderless R&D setup -- a strategic edge that allows us to not only meet global standards, but help set them.”

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American component major Tenneco India is no longer just manufacturing for the domestic market; it is transforming into a high-tech global export hub.

Under the leadership of CEO Arvind Chandra, the company is shifting from a ‘local-for-local’ strategy to a sophisticated ‘India for the World’ mandate that integrates Indian engineering into the global automotive lifecycle.

While current exports sit at approximately 6 percent, Tenneco’s future order book reveals a dramatic shift, with exports accounting for 20 percent of projected growth. This strategy leverages not only India’s competitive labour cost, but also high-quality innovations to bolster the margins of Tenneco’s sister divisions in Europe and the US.

"The addressable market just within Tenneco is huge," Chandra explains, noting that at present 70 percent of exports are currently directed to internal Tenneco entities. To support this, the company is earmarking USD 2 million for FY2026 to expand its R&D capabilities, creating a state-of-the-art centre to attract top-tier talent.

"When you become the export hub for the world, you should also become the R&D export hub," says Chandra.

Disrupting Ride Quality

On the domestic front, Tenneco is betting on ‘premiumisation’ in the passenger vehicle segment to disrupt the market. The company’s patented ‘DaVinci DCX’ suspension technology is at the heart of this push, aiming to bridge the gap between vehicle cost and ride comfort.

Chandra is candid about his goal to challenge the status quo of Indian roads: "My aspiration as CEO is to make sure that we completely disrupt the market. Because the comfort in the mass market passenger vehicle segment has been the same for the last 60-70 years".

Tenneco is also insulating itself against the uncertainty of electrification by remaining powertrain agnostic. Whether the market moves toward EVs, which can increase Tenneco's content per vehicle by over 4x for hybrids, the company remains positioned for growth. By ‘wrapping’ themselves around customer needs rather than protecting rigid revenue streams, Tenneco has secured a dominant 52 percent market share in shock absorbers.

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JSW Motors Limited, the electric and new energy vehicle subsidiary of the JSW Group, has entered into a long-term strategic agreement with Dassault Systèmes. The collaboration centres on transforming how the automaker will design, engineer and build its forthcoming models, with the DELMIA: 3DEXPERIENCE platform serving as the foundational digital framework for its entire lineup of new energy vehicles.

A key focus of the initiative is strengthening domestic capabilities. By merging local production expertise with globally recognised technology, the company aims to establish an automotive ecosystem that sets a new benchmark for India. This dual focus is designed to produce vehicles that meet international quality standards while being specifically calibrated for the domestic market, ultimately bolstering local supply chains and industrial resilience.

To advance this vision, the manufacturer is deploying the 3DEXPERIENCE platform to create a unified Product Lifecycle Management environment that spans design, engineering and validation. This effort is complemented by the integration of a sophisticated Manufacturing Execution System on the same platform, which ensures seamless digital continuity and full traceability from initial concept to final assembly.

Through this integrated approach, the partnership solidifies the company’s readiness to deliver competitive, future-ready vehicles. The unified digital infrastructure not only accelerates product development but also reinforces the organisation’s commitment to building a self-reliant, world-class automotive presence in India.

Ranjan Nayak, CEO, JSW Motors Limited, said, “At JSW Motors, we are building a technology-led future mobility ecosystem which is engineered in India and world class. We are delighted to partner with Dassault Systèmes from France to embed its state-of-the-art, digital platform across the vehicle lifecycle, from design to manufacturing at JSW Motors. We are also in advanced discussions with several additional domestic suppliers to further deepen localisation and strengthen India’s automotive supply chain. By leveraging the best global technologies, we aim to accelerate development timelines while enhancing quality.”

Deepak NG, Managing Director – India, Dassault Systèmes, said, “The Indian automotive industry is at a pivotal inflection point, and JSW Motors is well positioned to lead this transformation. Our 3DEXPERIENCE platform will empower JSW Motors to manage the growing complexity of software-defined vehicles while enabling end-to-end integration across their entire value chain, from design and engineering to manufacturing and lifecycle management. By building virtual twins of their products and processes, we will help drive greater innovation, efficiency and agility, ensuring scalability and sustained competitiveness in a rapidly evolving market.”

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Tensor, a Silicon Valley-based artificial intelligence firm, has introduced the Tensor Robocar to the United Kingdom at the 5th annual European AV Summit. The vehicle is the first production-ready Level 4 autonomous car designed for personal ownership.

The Robocar features a dual-mode strategy, allowing for both manual and fully autonomous operation. A key hardware innovation is the world's first foldable steering wheel, co-developed with automotive safety supplier Autoliv.

The vehicle architecture is built for full-stack redundancy to meet regional safety and reliability standards. Tensor's engineering utilises agentic AI and adaptive design to manage complex driving environments. The company has established a technical ecosystem through several strategic partnerships:

• Compute and AI: Collaboration with Arm for power-efficient compute platforms and Nvidia for AI processing.
• Infrastructure: Integration with Oracle for cloud systems.
• Manufacturing and Insurance: Partnerships with VinFast for scalable production and Marsh for insurance frameworks.

The UK appearance follows a global launch announcement in August 2025. The European AV Summit served as a platform to engage with regulators, insurers and city planners regarding the implementation of personal Level 4 ownership.

Tensor plans to commence production this year. Initial commercial availability is targeted for the UAE, EU and US markets.

Jay Xiao, Chief Executive Officer, Tensor, said, "Showcasing Tensor at the European AV Summit offered a vital opportunity to demonstrate a production-ready Level 4 vehicle to the policymakers, insurers and industry partners who shape Europe's AV future. Our purpose-built Robocar is engineered for full-stack redundancy providing a level of safety and reliability that combines agentic AI and adaptive design to meet rigorous regional safety standards. Tensor, showing for the first time in the UK, helped translate our technical evidence into practical pathways for safe, consumer ownership across European cities and soon - globally.

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