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!

Chinese automotive major Geely Auto has officially launched its i-HEV Intelligent Hybrid technology, which enters mass production immediately with the system slated for deployment across several models this year, including the Preface, Monjaro, Starray, and the fifth-generation Emgrand.

The technology utilises an artificial intelligence system and a dedicated hybrid powertrain to address historical gaps in fuel efficiency and smart feature integration.

The i-HEV system is built upon the i-CMA architecture, a hybrid-optimised version of the CMA platform that centralises the control of driving, cockpit and chassis functions.

A primary feature is the AI Cloud Power management system, which monitors exterior data such as temperature, humidity and altitude to optimise petrol-electric energy distribution. The company reports that this self-optimising strategy improves energy efficiency by more than 10 percent, while the engine achieves a thermal efficiency of 48.41 percent.

By decoupling the internal combustion engine (ICE) from the electric motor, the i-HEV adopts a motor-led layout designed to provide an electric-drive experience without external charging. The electric motor delivers up to 230kW, allowing the vehicle to operate on electricity for approximately 80 percent of the time. Performance data indicates a claimed zero to 30 kmph acceleration time of 1.84 seconds and a top speed of 66 kmph in electric mode.

The i-CMA architecture incorporates physical separation between oil and electric systems to enhance safety. Battery protection is managed through the Geely Battery Safety System, which includes a liquid-cooled battery with an IP68 resistance rating. The system is capable of real-time prediction for over 50 fault types.

Jerry Gan, CEO, Geely Auto Group, said, “Energy diversification is a strategic foresight for Geely Auto. A company’s true strategic focus is ensuring every path leads to the future, which tests the technological depth and powerful energy resilience of our entire system. The new i-HEV perfectly embodies this resilience, serving as a powerful testament to how artificial intelligence can elevate hybrid efficiency and performance to new industry standards.”

Comments (0)

ADD COMMENT

Link Copied!

Tsuyo Manufacturing (Tsuyo), an electric vehicle (EV) powertrain manufacturer, has been named as one of 15 Indian startups selected to represent the country in the deeptech category as part of the CII CIES Startup Delegation to Japan 2026.

The selection allows Tsuyo to engage with Japanese corporations during a period of increased EV expansion in Japan, aiming to establish long-term collaborations in engineering and supply chain integration.

The company specialises in electric powertrain solutions for three-wheelers, light commercial vehicles and heavy commercial applications, with a portfolio ranging from 0.5 kW to 400 kW.

Till date, Tsuyo has sold more than 200,000 motors and maintains partnerships with over 50 original equipment manufacturers (OEMs). The firm operates two manufacturing facilities in Greater Noida and focuses on research and development in collaboration with institutions such as the IITs and NITs.

In addition to its international engagement, Tsuyo recently received Single Window Clearance from the Government of Karnataka for a 20-acre manufacturing and validation campus in the Dharwad–Hubli region. This facility is intended to serve as a hub for the design, testing and large-scale production of powertrain components, reducing the domestic industry’s reliance on imported technology.

Vijay Kumar, Founder and CEO, Tsuyo Manufacturing, said, “Being selected for the CII CIES delegation is a proud moment - not just for Tsuyo, but for the evolution of India’s deeptech ecosystem. At Tsuyo, we see ourselves as a new age EV deep tech startup focused on co-creation, where innovation is built collaboratively across borders. India has the potential to engineer and scale world-class EV powertrain technologies, designed for real-world conditions and global applicability. Japan represents a strong strategic partner with its legacy of engineering excellence and disciplined manufacturing culture. Through this engagement, we aim to explore joint development opportunities, enable deeper supply chain integration, and contribute to the broader ‘Build India’ vision by strengthening local capabilities with global collaboration. Our approach to co-creation goes beyond technology - it extends to building robust supply chains, advancing futuristic mobility solutions, and aligning with the high standards of Japanese engineering. This is how we believe India will transition from being a growing EV market to a globally competitive EV technology hub.”

Comments (0)

ADD COMMENT

Link Copied!

Ola Electric has introduced the S1 X+ 5.2 kWh electric scooter, featuring the company’s indigenously developed 4680 Bharat Cell. The company claims that the launch marks the first time this cell technology has been integrated into a mass-market product. The e-scooter is available at an introductory price of INR 129,999 until 15 April.

The S1 X+ 5.2 kWh utilises an 11 kW mid-drive motor and an integrated motor control unit, providing a claimed top speed of 125 kmph and an IDC range of 320 km. It features a brake-by-wire system and front disc brakes. The use of the Bharat Cell reflects the company's strategy of vertical integration, which encompasses cell development, battery pack engineering and vehicle manufacturing.

Currently, Ola Electric’s portfolio includes the Gen 3 S1 scooter series and the Roadster motorcycle range. The S1 Gen 3 line-up consists of the S1 Pro+ and S1 Pro in various battery configurations, while the mass-market segment includes the S1 X+ and S1 X variants. The Roadster series is offered in X+ and X configurations with battery capacities ranging from 2.5 kWh to 9.1 kWh.

“With S1 X+ 5.2 kWh, we are taking our 4680 Bharat Cell to the mass market at scale. The same technology platform we built for our most advanced products is now powering a scooter designed for much wider EV adoption. This is exactly what vertical integration enables - the ability to innovate deeply, scale quickly, and bring our best technology to more and more customers, faster. S1 X+ 5.2 kWh is where performance, range and scale come together, and is another important step towards making EVs accessible to every Indian,” the company said in a statement.

Comments (0)

ADD COMMENT

Link Copied!

Bosch and Qualcomm Technologies, Inc. have announced an expansion of their strategic collaboration to include Advanced Driver Assistance Systems (ADAS). This move builds upon their established partnership in cockpit solutions and aims to address the automotive industry's requirement for scalable technology in automated and connected vehicles.

Bosch stated it has now delivered more than 10 million vehicle computers globally using Qualcomm’s Snapdragon Cockpit Platforms.

The extended agreement includes new production programmes for ADAS that utilise Bosch’s vehicle computer architecture powered by the Snapdragon Ride platform. A central component of this collaboration is the development of platforms that combine cockpit and ADAS functions on a single system-on-chip (SoC).

This integration is designed to align with the strategic shift towards software-defined vehicles, allowing automakers to reduce architectural complexity, power consumption, and manufacturing costs.

The Bosch ADAS integration platform is designed as a modular computer capable of fusing data from multiple sensors to create a 360-degree environment model. This system supports a range of functions from entry-level assistance, such as lane keeping and distance regulation, to higher-level automated driving. The joint engineering efforts have already secured several design wins in the East Asian market, with the first vehicles featuring these consolidated platforms expected to enter the market in 2028.

By migrating from numerous individual control units to a small number of high-performance computers, the partnership provides a path toward centralised vehicle architectures.

These solutions are engineered to meet safety standards up to ASIL-D while enabling consumer features such as hands-free driving and intelligent automated parking across various vehicle segments.

Christoph Hartung, Member of the Bosch Mobility business sector board, said, “By combining leading-edge compute technology with our system integration expertise – hardware, software, and safety – we enable automakers to meet the rising demand for personalised, safe and comfortable driving experiences. The growing success of our collaboration with Qualcomm Technologies underlines a central value Bosch brings to the industry: we provide the robust, high-performance computing platforms that form the backbone of today’s software-defined vehicle.”

Nakul Duggal, EVP and Group GM, Automotive, Industrial and Embedded IoT, and Robotics, Qualcomm Technologies, said, “Our collaboration with Bosch spans the full spectrum of vehicle compute – from high‑performance cockpit systems to scalable automated driving solutions and emerging centralised vehicle architectures – all powered by Snapdragon Digital Chassis automotive platforms. ADAS is where performance and safety must scale in the real world. By expanding our work with Bosch into production-ready ADAS platforms, we’re helping automakers bring advanced driver assistance across vehicle lines more efficiently, with a clear path to centralised compute.”

Comments (0)

ADD COMMENT

Link Copied!