Motion plastics manufacturer, Igus India expanded its footprint in the country by inaugurating a new manufacturing plant spanning 92,000 square feet in Bengaluru Thursday. 

The state-of-the-art plant in Mandur near Budigere in Bengaluru comes at a point when the company prepares to focus on new divisions dedicated to the semi-conductor and renewable energy sectors, areas poised for substantial growth. The expansion is part of Igus’s long-term strategy to enhance its operational capabilities and support its extensive customer base in India.

The newly inaugurated facility is a testament to the company’s long-term commitment to India, involving an investment of over INR 1 billion. This financial outlay reflects the company’s dedication to maintaining its competitive edge through innovation and cutting-edge technology. 

Of the total investment, INR 200 million have been allocated for setting up the factory, INR 400 million for advanced injection moulding machines and INR 200 million for enhancing the manufacturing process. The plant’s infrastructure is designed to meet the high standards of motion plastics production, ensuring that Igus India continues to deliver world-class products tailored to the unique demands of the Indian market.

Since its establishment as a wholly-owned subsidiary in 2000, Igus India has become a prominent player in the motion plastics industry, catering to over 19,000 customers across the country. The company’s extensive product catalogue boasts 125,000 parts, which are used in a variety of customer-driven assemblies, many of which are customized and assembled locally. This vast array of products underscores Igus’s commitment to innovation and customer satisfaction, with over 200 new products introduced annually. The company’s ability to adapt to the evolving needs of its customers has been a key driver of its success in the competitive Indian market.

Looking ahead, Igus India has ambitious plans to further strengthen its operational capabilities and market presence. The company is eyeing significant revenue growth, with expectations of reaching INR 3.4 billion in revenue this year. To support this growth and enhance its logistical efficiency, Igus India plans to establish new logistics and assembly centres in Pune, Gurugram and Noida. These new facilities will enable Igus to better serve its customers across India, reducing lead times and improving overall service delivery.

The focus on emerging industries like semi-conductors and renewable energy is a strategic move by Igus India to align itself with sectors that are poised for substantial growth in the coming years. As India continues to invest in its semi-conductor manufacturing capabilities and renewable energy infrastructure, the demand for high-quality motion plastics is expected to rise. Igus India’s expansion positions the company to capitalise on these opportunities, offering innovative solutions that meet the specific needs of these rapidly growing industries.

The opening of the new manufacturing facility in Bengaluru marks a significant milestone for Igus India, reinforcing its position as a leader in the motion plastics industry. With a strong commitment to innovation, customer satisfaction and market expansion, Igus India is well-positioned to achieve its growth objectives and continue delivering value to its customers across the country. 

Emphasising the strategic importance of this expansion, Igus India Managing Director Deepak Paul stated, “The Indian market presents tremendous potential for Igus as demonstrated by our continued growth and investment here. Our objective is to deliver cutting-edge products and solutions not only to our customers in India but also on a global scale. Igus’s global focus on cost-sensitive and sustainable solutions, encapsulated in our motto ‘Tech up, cost down,’ is perfectly aligned with the Indian approach to technology and innovation. This alignment has been a key driver of our significant growth in the country. As we look forward, our plans include expanding beyond Bengaluru, with logistics and assembly centres set to be established in Pune, Gurugram, and Noida.”

 Igus India is currently the 6th largest subsidiary among Igus’s 38 global subsidiaries, a position that reflects its strong performance and growth potential. Over the past two years, Igus India has doubled its market growth, with revenue figures climbing from INR 1.99 billion to INR 3.13 billion. The company expects this upward trajectory to continue. Additionally, Igus India has invested in a clean room testing facility in Germany and plans to establish a similar setup in India, further enhancing its product development and quality assurance capabilities.

Commenting on the occasion, Country Manager and Director Santhosh Jacob said, “Technology and innovation are at the core of everything we do at Igus. With a catalogue of 125,000 parts and 247 new products introduced this year, we are constantly inspired by our customers’ needs to push the boundaries of what is possible. Our ongoing expansion of the motion plastics product world, coupled with the integration of digitalization and AI, is a testament to our long-term corporate strategy. We are making significant progress in embedding digitalization as a key technology at Igus, which will play a crucial role in our future growth and success.”

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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.”

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Anaphite, a UK battery technology startup, has released the results of an independent sustainability assessment of its dry coating technology platform for battery electrode manufacturing. The analysis, conducted by life cycle assessment experts Minviro, found that Anaphite's patented technology reduces carbon emissions by 3.57 kg CO2 eq. per kWh of cell capacity compared to the wet coating process.

At present, it is estimated that wet coating is used for over 99 percent of electrode production globally. It is energy-intensive due to the ovens needed to dry electrodes. Dry coating processes eliminate this drying oven.

Anaphite’s patented platform combines all ingredients of a battery electrode into a single engineered material, which is optimised for high-speed dry coating lines. The company states this approach solves the challenges of achieving dry coating at scale, unlocking carbon emissions savings for battery and EV makers.

• If Anaphite’s technology were to completely replace wet coating for every cell made in 2025, it would save 7 million tonnes of CO2.
• For a 75 kWh battery pack, the technology can deliver a 268 kg CO2 eq. saving.

With global annual demand expected to double by 2030, the adoption of dry coating is imperative to maximise environmental benefits.

Joe Stevenson, CEO, Anaphite, said, “Wet coating of electrodes is well proven, but manufacturers want it replaced by dry coating because of the carbon footprint improvements and cost reductions it delivers. Our unique dry coating process technology is the solution manufacturers need to make EVs more sustainable. We’re delighted to see its environmental benefits confirmed by Minviro’s independent assessment. We’re scaling-up the Anaphite technology platform at our facility in the UK and deepening our in-house dry coating capabilities and expertise. We are working in close collaboration with the global automotive industry to bring dry coating to market.”

Lydia Bridges, Senior Consultant, Minviro, said, “Collaborating with Anaphite on this study has been a great example of how rigorous, transparent assessment can translate innovative process design into quantifiable results. Our independent analysis identified a clear reduction in carbon footprint for Anaphite’s dry coating process compared with conventional wet coating, using ISO-aligned methods and critical review. Studies like this that follow the Environmental Footprint (EF) method provide essential environmental data for cell manufacturers, as this method forms the basis of the EU Battery Regulation carbon footprint quantification.”

The assessment is compliant with the ISO-14067 standard and the climate change model aligns with that proposed for the incoming EU Battery Passport regulations. These regulations will be mandatory from 2027 for EV and industrial batteries over 2 kWh, requiring the reporting of each battery's total carbon footprint. The work was part of a Feasibility Study project funded by a grant from the UK Government under the Automotive Transformation Fund (ATF).

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Italian automotive majors Alfa Romeo and Maserati have joined forces to establish BOTTEGAFUORISERIE, a new automotive excellence hub in Italy's Motor Valley. This initiative aims to shape bespoke automotive experiences by merging tradition, craftsmanship and technology.

The project encompasses a broad area extending from Modena to Turin and Arese (Milan province), bringing together the legacies of both manufacturers. Cristiano Fiorio has been entrusted with the leadership of BOTTEGAFUORISERIE, reporting directly to Santo Ficili, Alfa Romeo CEO and Maserati COO. The initiative was established under the patronage of the Altagamma Foundation.

BOTTEGAFUORISERIE will focus on several main thematic areas: BOTTEGA, FUORISERIE, Corse and La Storia (History).

• BOTTEGA: This serves as the 'sartorial heart,' dedicated to developing and building 'few-off' limited edition projects, such as the Alfa Romeo 33 Stradale and the Maserati MCXtrema. This work involves collaboration with the customer to create a unique piece.
• FUORISERIE: This offers advanced personalisation, allowing customers to turn their car into a unique model. A design team will explore new creative vernaculars while remaining faithful to the brands’ aesthetic codes.
• Corse: Focused on motorsport, this theme transforms racing know-how into engineering innovation for super sports cars. Maserati Corse serves as a driving force, leveraging racing solutions to evolve the cars.
• La Storia: This initiative preserves the historical heritage of both brands through restoration and certification of vintage cars, and the creation of archives and museums, including the Alfa Romeo Museum in Arese and the Umberto Panini Maserati Collection in Modena.

Santo Ficili, CEO, Alfa Romeo and COO, Maserati, said, “This launch is more than the creation of a new initiative – it is the symbol of a new era for Alfa Romeo and Maserati. It represents our unwavering belief in the power of Italian creativity, engineering and craftsmanship. I am proud to entrust this mission to Cristiano Fiorio; his exceptional work on projects like the Alfa Romeo 33 Stradale and our motorsport programmes has demonstrated not only technical mastery but also a deep emotional connection to the soul of our brands. This is the first milestone in a broader transformation that will define the future of both Alfa Romeo and Maserati.”

Jean-Philippe Imparato, Maserati CEO, added: “We are extremely proud to announce this extraordinary joining of forces between two iconic brands. BOTTEGAFUORISERIE represents the meeting point between vision and reality. This is where dreams will be shaped into reality, where the extraordinary becomes tangible. Guided by creativity and discipline, each project is the result of rigorous research and unwavering dedication. By combining the finest in Italian design, engineering, and culture, BOTTEGAFUORISERIE embodies a unique approach to shaping the future – one we deeply believe in.”

Cristiano Fiorio, BOTTEGAFUORISERIE General Manager, said, “Being entrusted with the leadership of BOTTEGAFUORISERIE is both a profound honour and a thrilling challenge. This is somewhere where past, present and future converge – where we celebrate our heritage while daring to imagine what’s next. I will draw on the incredible experiences gained through special projects and motorsport to guide this new journey. With a team of passionate, talented individuals, we will craft vehicles that are not only technically exceptional but emotionally unforgettable. Our mission is clear: to honour the legacy of Alfa Romeo and Maserati, and to write the next chapter in their history with boldness, beauty and authenticity. Performance is an act of culture. Creating beauty is a form of art.”

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German component supplier Eberspaecher is expanding its product portfolio with two new heating solutions for 800-volt electrical systems in battery electric vehicles (BEVs).

The company states that optimised thermal management is important for addressing challenges in electromobility, such as battery range, charging times and comfort.

Eberspaecher is introducing a coolant heater with thick film technology and an air heater with PTC technology. Both systems provide demand-based heat output for the passenger cabin and battery conditioning and can be integrated into OEM systems on a modular basis.

The new coolant heater uses thick film technology (TFE), offering a compact and powerful alternative to classic PTC technology.

• Heat Output: The component conditions the vehicle battery and achieves up to 12 kW of output at 800-volt, contributing to extending battery life and reducing charging times.
• Voltage Flexibility: The heater delivers sufficient output even at 400-volt, ensuring compatibility with the current charging infrastructure.
• Safety: The safety concept includes multiple sensors and an independently operating second shutdown path.

The thick film heater is suitable for passenger cars and trucks and has been selected by several automobile manufacturers for use in their series lines. Production is scheduled to begin in 2027.

On the other hand, the air heater, which is installed directly in the air-conditioning system, uses PTC technology.

• Multi-Zone Function: The heater features a multi-zone function allowing the driver to control the temperature separately in up to four zones in the interior, such as different temperatures for the driver and front passenger sides.
• Power Range: The heater is designed to accommodate both 400- and 800-volt architectures, with a power range of 3-8 kW.
• Emissions: Eberspaecher avoids using adhesives in the setup of heating elements wherever possible, minimising the risk of unwanted emissions in the passenger compartment.

The product will be available in Asia, Europe and North America starting in 2028.

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