Stratasys, a global leader in additive manufacturing or 3D printing technology, helps Indian aerospace, automotive, healthcare and consumer products industries design and make prototypes, manufacturing tools, and production parts faster and cost effectively.

Several OEMs and Tier-1 companies in these industry segments are its customers who want high value products at very reasonable prices. In an interaction with T Murrali of this publication, Rajiv Bajaj, Managing Director, Stratasys India and South East Asia, said, “We are changing the game by giving industrial production-grade machines at affordable prices. We have a lot of takers for them across industries in the Tier-2& 3 cities also.” Edited excerpts:

Q: In India, is additive manufacturing still confined to R&D for making prototypes? What is the next step in the automotive sector?

Bajaj: The car companies we have in India are globally competitive, keeping pace with what is happening around the world. The differentiation we see as a technology provider is the level of technology adoption by the local OEMs. Similar-sized OEMs elsewhere in the world will have a series of our machines whereas in India they are just 1 or 2 each, most of them with the auto OEMs. It also has to do with the technology adoption rate and the trend of product development and differentiation which came in rather late.

 Secondly, prototyping is a well documented area; people use it day in and day out. Companies like Honda, that do only manufacturing in India, are adopting it for their jigs and fixtures. The third stage we look at is personalisation where one can use the 3D printed part in a portion of the vehicle, which has been done with BMW MINI, and Daihatsu in Japan. We don’t have any use case in India as yet. We are looking at possibilities here.

Q: Are there some applications where it can be used?

Bajaj: Now we are talking about not just back-end or R&D use but actual customer experience. There we are giving tooled-up parts with multiple finishes. There are finite possibilities with the new numbers and quality of parts being manufactured. 3D is also used as a marketing tool. Typically, people look at it as a device to save money or time as this is a revenue generation tool.

Q: So even if you make 10,000 parts, each one can be customised?  

Bajaj: Yes, absolutely; it’s mass customisation.

Q: Do you see opportunity globally and in India to replace traditional manufacturing by 3D, and to what extent?

Bajaj: There is no simple yes or no answer to this. It involves a deep understanding of how the two processes work. If volumes are a few thousands, yes; but if it is in lakhs, then maybe not. The most intelligent organisations would be the ones who would use a mix-and-match of this technology. Additive doesn’t mean it should remove subtractive. Intelligence lies in knowing when to use additive and where to leverage subtractive, and vice-versa. Combining these two will make for a very efficient organisation.

Q: Will this find a key role in low volume parts? 

Bajaj: Yes, as well as complicated parts and in the aftermarket for different models. Even enthusiasts like Jay Leno will find a use for this. In fact Leno has bought a 3D printer from Stratasys to make parts for his collection of vintage cars. It’s a useful tool for motor enthusiasts to make parts that are not available in the market.

Q: Do you see additive manufacturing for lightweighting?

Bajaj: Parts consolidation is a very direct outcome of 3D printing because, for example, it can print a chain with interlock whereas in the traditional process each part would be a separate entity. In an aerospace part we consolidated some 100 plus parts into one unit. In automotive, now many areas for this are emerging for limited production; mass production would take some more time but it will come. When we talk of lightweighting, making prototypes earlier was quite difficult but today with this technology we can make very complex prototypes and validate the design. Once it is validated it can use any method: for low volume additive, for high volume something else. That’s the advantage. Also, in assembly, we can check minute gaps in the line very accurately. Changes in tooling can be done immediately instead of waiting for a long period as customisation has to be done in the shortest period possible.

Q: Would this help reduce the number of iterations?

Bajaj: Actually I can do more iteration by trying out newer ideas. This will help enhance the quality level at the design stage itself. We have to find a balance between the additive and the subtractive.

Q:  Would the customer complaints reduce when you make a product faster?

Bajaj: Obviously, as I am designing quality into the process and product from day one; it helps me take informed decisions. Basically, what the customer wants is a good, tangible product.

Q: What is the response you get from customers who have not taken up this technology as yet?

Bajaj: In today’s scenario there would be very few customers in the automotive supply chain who have not experimented with 3D printing. If they are not using it directly they are getting services done outside. The expectations from customers is different; some want better quality, some want it faster, some cheaper and so on. Most of them are experimenting so that this should become a part of their process.

Q: Are there other concerns than cost?

Bajaj: In India, cost is a big concern; customers want high value at the most reasonable price; they are not looking just for low cost. So there is pressure; that’s why a lot of innovation helps. A company cannot just copy paste; it has to innovate. In 2015 our lowest cost of the printer in FDM series was around INR 60 lakh. Today, we have given the same technology on a different platform for INR 15 lakh. That’s how we are changing the game, giving the same class of industrial production grade machines at an affordable price. This has found a lot of takers for us in the Tier-2&3 cities, not just automotive but across industries.

Q: There might be apprehension among your potential customers that if they buy a machine from you they would have to be wedded forever to your company to get the material. Is that true or will they be free to choose their own material from the market for use?

Bajaj: For most of our technologies it is true but we are working on a new technology called SLA which is our only platform where the consumer can buy material elsewhere. The problems with 3D printing are many. Let us say if you make your material open and then the customer comes and says the parts are not printing correctly; then where do you fix the blame? That becomes a big problem. The reason why we keep it to us is not because we want to charge customers more, but because we want to give them 100 percent accurate results all the time. Predictability and repeatability are problems that 3D printers at entry level are facing every day. By controlling the oven temperature and the material properties we are able to achieve 100 percent accuracy. When companies like Maruti tell us there are some challenges, we work with them to sort it out.

It is like when the customer buys a car and goes to the spurious market to get parts. When the vehicle fails they come and complain to us. We check the car and tell them the company is not responsible for whatever parts the customer fits in. Even insurance companies do not entertain such claims. If you want consistent quality and most desirable product performance you will have to stick to some standards.

Q: Do you see Stratasys to become even a supplier to vehicle manufacturers or Tier-1s?

Bajaj: It is not done in India as yet but globally we do run Service Bureaus. The BMW MINI project is all done by our Bureaus.

Q: Is this like software as a service where they can use your facility?

Bajaj: Yes, they have to just give us the software data and we will be able to print it. But that is not the real intelligence of the service bureau. The services we provide are very high-end; redesigning the entire thing, adding more colour variants, giving a new look to the car. These are the kind of services we provide where 3D printing is a part of the process. We take into account all the special requirements the customer wants. We have done complex projects in India and our overseas offices as a service.

Q: Which are the markets that are very attractive, where you have more inroads as of now? Going forward, how will it be?

Bajaj: Automotive is our sweet spot, globally (around 25 percent) and in India (30 percent). I see it as a major place for expansion because compared to global standards the technology adoption with these companies is very low. I believe if they have to compete in testing times like this there is no other way than to come out with products faster and cheaper. Technologies like Stratasys 3D printing are tailor-made for this. Despite the slowdown we are very bullish about the automotive market because of the lack of penetration in it. It’s a technology life cycle, similar to the software industry where the cycle came from the US and went on to Europe and to Asia before coming to India.

Q: How do you compare with aviation as you are the only one certified by the aviation industry?

Bajaj: For aviation, we are limited to plastics at this point in time so the parts made by us are more suitable for the cabin interior. India is more about defence aviation where the aircraft interior is not that critical. While HAL, DRDL, etc are all using our technology, mass proliferation would occur when companies like Boeing and Airbus have their complete setup in India. We need civil aircraft to be manufactured in India to see that kind of growth; there are none at present.

Q: For automotive, what are the key drivers of growth globally and in India?

Bajaj: One is the quest for innovation through rapid prototyping. Two, the product development cycle time has reduced by 50 percent in the last four years. If a new platform time was 3 years earlier, today it is under 18 months. In the past two years, any automotive company that has not come up with newer models at a faster pace has not survived. To keep the momentum going in the market they have to come up with new products. If they have the right product at the right price in India their business will certainly grow. (MT)

 

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User Forum

The 3rd edition of Stratasys India User Forum in Bengaluru recently had participation from over 620 industry leaders and end-users. Organised by Stratasys, a global leader in 3D printing and Additive Manufacturing (AM), the Forum was a platform for professionals to exchange views on the latest 3D printing trends, applications, and the best practices across key sectors in India.

Michael Agam, President, South Asia, Stratasys, said the User Forum brought together several leading brands such as Maruti Suzuki, Ashok Leyland and Honda Cars in the Indian ecosystem, that have used Stratasys’ products to innovate. This reiterates why India is a key market for the company.

Saurabh Singh, Head of Design Studio at Maruti Suzuki India Ltd, highlighted how the brand has been able to leverage 3D printing to provide high quality, ergonomically suited and distinctly personalized offerings, thereby enhancing the overall customer experience.

Sundaresan, Vice-President, Electric Vehicles and eMobility Solutions, Ashok Leyland, said that AM helped the company save about 14,138 days of hour-utilization and nearly INR 74 lakh in manufacturing costs. He said Ashok Leyland made clutch housing using AM to carry out fitment checks and it helped to contain the time to three days against close to 60 days in the conventional method. AM helped also to keep the time schedules for the development of blower cover and meet the CMVR regulations. The company made prototypes and parts for the initial production lot. The whole exercise was completed in a couple of days as compared to 90 days in the conventional method. Similarly, the three-axis intake pipe was made in a day as opposed to the usual three months. It also made a scaled concept of the seven-speed gearbox having geometric complexity. For electric vehicles the company made traction motor stator sector in AM, which helped in physically measuring the slot-fill, evaluate ease of winding and measure external portions of end-winding. “For smaller volumes also AM is economical. For advanced mobility it plays a key role in the combustion chamber”, Sundaresan added.

Bhushan Chandna, Manager, Business Excellence, Honda Cars, explained how the brand has spearheaded the use of additive manufacturing in the auto sector, especially with the use of 3D-printed jigs and fixtures. (MT)

Honda R&D, a subsidiary of Honda Motor Co., has developed underlying technology for a magnetic coupling wireless power transfer road system in partnership with Taisei Corporation and Taisei Rotec Corporation.

The system enables wireless in-motion charging for electric vehicles, including passenger cars and heavy commercial fleets. The partners plan to initiate demonstration testing on public roads starting in FY2027.

The technology integrates high-power-density receiver and transmitter units from Honda with a high-response direct current power supply system from Taisei and road-embedding construction techniques from Taisei Rotec. By supplying power to electric vehicles while in motion, dynamic wireless power transfer reduces the need for stationary charging infrastructure. The initial commercial focus targets logistics and transport operations, where continuous operation offers economic benefits.

The ground assembly embedded in the roadway combines the inverter and coil into a single unit designed to connect via direct current distribution. This design reduces component counts, simplifies wiring and supports installation into existing road surfaces through standard milling methods. The road pavement structures are engineered to withstand continuous traffic loads from vehicles weighing up to 20 tonnes (20,000kg).

Testing conducted at Taisei Group’s T-FIELD facility in Satte verified system stability and structural durability. Starting in late 2026, the companies will build a test roadway at T-FIELD Tamura to evaluate long-term durability under one million wheel-load cycles, measure power transfer efficiency at outputs up to 150 kW and analyse electromagnetic shielding.

The partnership will also join the Tateyama Expressway demonstration project managed by East Nippon Expressway Company starting in 2027.

Czech automaker Skoda Auto has expanded its powertrain portfolio with the introduction of a full hybrid powertrain for the Octavia, marking the first time the marque has offered this technology. The new powertrain is available for both hatchback and estate body styles in the Selection and Sportline trim levels.

The new Octavia utilises a series-parallel hybrid setup that combines a 1.5 TSI evo2 petrol engine with two electric motors, a single-speed automatic transmission and an automatic clutch that connects the engine directly to the front axle.

The smaller electric motor functions as a generator and starter, whilst the larger motor drives the front wheels and recovers energy during deceleration. The system automatically selects between all-electric, series hybrid, and parallel hybrid operation depending on speed, driver demand and battery charge levels. Electric mode offers a driving range of approximately two kilometres.

The model is offered in two power outputs: a 100 kW variant using a 96 kW petrol engine and a 125 kW version paired with a 110 kW engine. Both variants share identical electric motors and have an electronically limited top speed of 180 kmph. Energy is stored in a 1.6 kWh battery positioned beneath the rear seats, paired with a 40-litre fuel tank. Boot capacity is rated at 460 litres for the hatchback and 485 litres for the estate. Standard features include a 13-inch infotainment display and a 10-inch digital instrument panel. Orders open in October, with customer deliveries scheduled to begin in December 2026.

Johannes Neft, Chief Development Officer, Skoda Auto, said, "The Octavia is the first Skoda model to feature a full hybrid powertrain. Its series-parallel hybrid system combines a combustion engine with the flexibility of electric driving. Operating fully automatically, the system selects the most efficient drive mode according to the current conditions. The traction battery is recharged while driving by the combustion engine or through energy recuperation. With two output levels available for both the hatchback and estate, the full hybrid adds another technically versatile option to our powertrain portfolio giving customers even greater choice to match their individual needs."

The Automotive Research Association of India (ARAI) and COEP Technological University have signed a Letter of Intent to establish the Advanced Ergonomics and Human Factors Research Centre (AEHFRC) at COEP Tech’s Research and Innovation Park in Chikhali, Pune.

The initiative involves a planned investment of INR 1.05 billion and will function as a national facility focused on developing technologies tailored to the physical metrics of Indian users.

The facility will span approximately 38,000 square feet. The project will be executed in two phases: the first phase, spanning two to three years, will set up laboratories for posture evaluation, seating comfort analysis, human biomechanics and field of vision assessments; the second phase, over four to five years, will complete the full-scale deployment of the centre.

The centre will address sectors including automotive, defence, aerospace, railways, agriculture, industrial equipment, consumer goods and textiles. Key operational objectives include generating Indian anthropometric databases, establishing ergonomics standards, creating usability frameworks and offering training and certification programs.

The partnership will pursue research projects, consultancy assignments, and funding from government bodies, industry partners, and CSR initiatives to translate academic research into industrial applications.

Dr Reji Mathai, Director, ARAI, said, "As technology becomes increasingly human-centric, ergonomics and human factors play a critical role in ensuring safety, usability, and user well-being. Through this partnership with COEP Technological University, ARAI aims to create a national ecosystem that advances research, develops indigenous capabilities, and supports industry in creating products and systems that are better suited to Indian users and operating conditions. We believe the AEHFRC will play a significant role in strengthening India’s capabilities in human-centred design and innovation."

Prof. Sunil Bhirud, Vice-Chancellor of COEP Technological University, said: "COEP Technological University has consistently worked to translate research into societal impact. The proposed AEHFRC, in collaboration with ARAI, will provide a unique platform for interdisciplinary research, innovation, and industry engagement in ergonomics and human factors. We are confident that this initiative will contribute significantly to the development of Indian standards, indigenous technologies, and a skilled workforce capable of addressing national and global challenges."

MathWorks and MapmyIndia Mappls have announced a collaboration to support automotive engineering teams developing and validating Advanced Driver Assistance Systems (ADAS) for Indian driving environments.

Under the partnership, MapmyIndia’s high-definition (HD) digital maps have been integrated with MathWorks' software ecosystem, including MATLAB, Simulink and RoadRunner.

The integration enables engineers to construct digital twins of Indian road infrastructure to simulate traffic scenarios and evaluate ADAS controllers within a Model-Based Design framework before physical vehicle testing.

MapmyIndia’s HD maps capture lane-level geometry, traffic controls and localised road features, including speed breakers, potholes and worn lane markings. The dataset addresses engineering challenges associated with Indian traffic environments, such as high-density traffic, variable lane discipline and evolving road layouts.

The combined software workflow links location intelligence data directly into algorithm development and system validation tools, aiming to reduce virtual testing cycles for original equipment manufacturers and tier-one automotive suppliers operating in India.

Sapna Ahuja, President of Automotive Business and Chief Operating Officer, MapmyIndia Mappls, said, "India's roads present some of the world's most complex and dynamic driving environments. Developing ADAS solutions for these conditions requires far more than adapting models built for structured traffic ecosystems. MapmyIndia's HD maps capture the scale and complexity of Indian roads with accuracy and detail — from lane-level geometry and traffic controls to speed breakers, potholes, faded lane markings and other critical localised road attributes. Our collaboration with MathWorks empowers automotive engineers to simulate real Indian driving conditions, validate systems earlier, and accelerate the development of ADAS solutions that are truly built for India."

Vijayalayan R, Senior Manager – Automotive, MathWorks, said, "As automotive teams expand ADAS development for India, virtual validation is becoming essential to evaluate system performance across diverse driving conditions. By integrating MapmyIndia’s HD maps with MATLAB, Simulink, and RoadRunner, engineers can test ADAS algorithms earlier in development, reduce reliance on costly physical testing, and improve system performance before deployment on Indian roads."