Zebra Technologies Corporation released the findings of its Automotive Ecosystem Vision Study. The study aimed to gauge industry views, priorities and expectations the industry faces, and the challenges and opportunities resulting from rapid digital transformation. All data was collected and tabulated by third-party research firm, Azure Knowledge Corporation.

The study confirmed automotive manufacturers are under pressure to accommodate growing consumers’ preference for electric vehicles (EVs) in the near future. Automotive manufacturers must plan for a smooth transition to EVs, which have a very different requirements from raw materials to final assembly. Technology-led priorities will therefore be focused on increasing automation, building in-house technologies and expanding visibility across their respective production and supply chains. 

The survey was conducted from August to September 2022, with participation from 1,336 respondents globally, including industry decision-makers, fleet managers and consumers. In APAC, the 350 respondents were surveyed across India, Greater China, Japan and South Korea.

APAC consumers, including India respondents, will prefer purchasing EVs in the future
The survey reflects that in the near future there will be a shift in preference, with more than half of consumers (53 percent globally, 60 percent in APAC, including India) indicating going for a hybrid electric vehicle (HEV). However, navigating this increasing demand for EVs comes with challenges as 68 percent of global automotive industry decision-makers (60 percent in APAC, including India) say they are under high pressure to produce next generation (electric) vehicles, while 75 percent of them (71 percent in APAC, including India) are under high pressure to deliver products that are more eco-friendly, sustainable and safer for the environment.

The study also highlights consumers across generations pushing automotive manufacturers’ acceleration to technology innovation as eight in ten say that sustainability and eco-friendliness are key priorities in their vehicle purchase and lease decisions. 87 percent of millennials prioritise sustainability in their vehicles followed closely by 78 percent of Gen Xers and 76 percent of baby boomers. Within APAC, 85 percent of consumers were aligned with these key priorities, consisting of 92 percent of millennials, 83 percent of Gen Xers and 72 percent of baby boomers prioritising sustainability the highest.

Consumers are driving the growing emphasis on personalisation – the ability to customise a vehicle to their liking. Nearly four in five consumers say personalisation options factor into their decision to purchase a vehicle, and eight in ten fleet managers share these same requirements for sustainability and personalisation. APAC consumers resonate with this most strongly when compared with their global counterparts, with 86 percent prioritising personalisation options in their purchasing decisions, and 92 percent of fleet managers sharing the same requirements.

While nearly 80 percent of automotive industry decision-makers globally (77 percent in APAC, including India) recognise consumers expect more sustainable and personalised vehicle options today, around seven in ten concede it’s difficult to keep up with increasing customisation demands. As a result, three in four automotive manufacturers globally say a top priority is to build strategic partnerships with tech companies for their next generation of production. This number is lower across APAC, at 72 percent and 64 percent respectively.

Tan Aik Jin, Vertical Solutions Marketing Lead APAC, Zebra Technologies, said, “The challenges that automotive manufacturers face today include finding and retaining qualified workforce, navigating supply chain disruptions, delivering on heightened expectations around speed and accuracy. While it’s heartening that consumers are leaning towards a greener automotive future with greater preference towards electric vehicles, this is a signal to automotive decision-makers to actively invest more in safer technologies and robust infrastructure, to better serve their customers.”

Trust and transparency in automotive manufacturing
Data and information transparency is highly important to consumers and fleet managers alike, and they are seeking more visibility into the automotive ecosystem. When considering a vehicle for purchase or lease, 81 percent of consumers globally (85 percent in APAC, including India) and 86 percent of fleet managers (92 percent in APAC, including India) indicate they want to understand the origin of materials and parts on their vehicle. Millennials lead the way in demanding more transparency in automotive manufacturing, as more than eight in ten (both globally and in APAC, including India) say it is important to have access to manufacturer information along with knowing if source materials and parts are sustainable and understanding how the vehicle is manufactured from end-to-end.

Beyond gaining greater visibility into the automotive manufacturing process, once they have their vehicles, 88 percent of consumers (82 percent in APAC, including India) and 86 percent of fleet managers (88 percent in APAC, including India) want to understand how the data from their vehicles will be used by the automotive ecosystem.

After a vehicle purchase, 83 percent of consumers and 84 percent of fleet managers expect ownership and control of the data their vehicle generates. This sentiment is similarly shared within APAC, by 86 percent of consumers and 88 percent of fleet managers.

Automotive supply chain visibility
A majority of consumers (79 percent globally, 83 percent in APAC, including India) and fleet managers (81 percent globally, 84 percent in APAC, including India) want end-to-end visibility during the manufacturing process. However, only around three in ten automotive industry decision-makers say they will prioritise connecting real-time data systems (30 percent in APAC, including India) to enable a holistic view of operations and increase visibility across production and throughout the supply chain over the next five years (32 percent in APAC, including India). 

Jin added, “To provide real-time visibility throughout the supply chain, digitising operations via RFID and rugged handheld mobile computers can ensure that both regulations and sustainability expectations are met effectively and efficiently.”

Slightly more than one-third of OEMs globally and in APAC said autonomous mobile robots (AMRs), RFID, rugged handheld mobile computers and scanners as well as industrial machine vision will improve supply chain management. Similarly for suppliers, one-third of those surveyed cite mobile barcode label/thermal printers, wearable computers and location technology as the technologies to do so. 

Rajnish Gupta, Vice President and Head – India and Sub-Continent Business, Zebra Technologies, said, “Manufacturers are innovating to meet changing customer demands, and they are increasing their investment in technologies to deliver more personalised and sustainable vehicles. Along with this, they also need to ramp up their end-to-end supply chain visibility to build the next level of trust with their customers. We are ready to help automotive manufacturers enhance their operational capabilities through digitalisation through varying solutions like the L10ax rugged tablet, RFD90 ultra-rugged UHF RFID sleds, MC9300 DPM mobile computer and Workforce Connect, just to name a few.”

Overall, around seven in ten automotive industry decision-makers (76 percent globally, 67 percent in APAC, including India) agree that digital transformation is a strategic priority for their organisation. In the next five years, they anticipate expanding their use of technology, with 47 percent (both globally and in APAC, including India) focused on additive manufacturing/3D printing and 45 percent globally (46 percent in APAC, including India) on supply chain planning solutions.

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AutoVRse, a Bengaluru-based enterprise VR platform, has secured USD 2.4 million in a funding round co-led by Singularity AMC’s Large Value Fund III and Early Opportunities Fund, with continued participation from Lumikai. The investment arrives as automotive manufacturers face pressure from the EV transition, complex assembly, supply chain disruptions, labour shortage, and production line defects. Many of the world’s largest auto makers have already turned to AutoVRse’s technology.

The company provides VR simulation and smart-glasses-enabled field guidance for manufacturing, heavy industry and energy. It serves over 500,000 users across 50 enterprise clients in North America, Europe the GCC, and India, including Bosch, TVS Motors, Ashok Leyland, Tata Autocomp, Panasonic, KPIT and Godrej.

Three forces are driving Indian automotive interest in AI-driven training. The EV shift has made legacy internal combustion engine training obsolete, forcing manufacturers to rebuild training libraries. A shortage of skilled labour has made faster onboarding a necessity. AI-powered smart glasses now enable real-time guidance for line workers. Use cases include assembly training for new vehicle launches, EV battery safety, quality inspection and technician training for ADAS-equipped vehicles.

With the new capital, AutoVRse plans to expand its smart-glasses-based guidance product, which it believes will become standard on assembly lines within two years. It also aims to scale its North American presence, where deployments are running at several Fortune 500 firms, while strengthening its dominance in India and the GCC.

Ashwin Jaishanker, Co-Founder and CEO, AutoVRse, said, “AutoVRse moves safety and training culture from documentation to evidence. Our training products meet workers where they are – e-learning modules, dynamic SOPs, VR simulations – so they're certified before they ever go on-site. Our AI products replace tedious safety busywork like form-filling and performative inspections with real intelligence: helping workers make better decisions in dangerous situations or catch unsafe conditions before they arise. We're grateful to Singularity AMC for backing this vision, and to Lumikai, who've believed in this bet for years.”

Vikram Jaish, Head – HSE, WCL Pipes Anjar, Welspun Corp, said, “Pipe coating operations involve multiple high-risk touchpoints where early hazard recognition is critical. With AutoVRse’s VR training, our teams can experience and identify these hazards in a realistic, controlled environment before stepping onto the shop floor. This has significantly improved awareness, preparedness and safe decision-making compared to traditional training methods.”

Yash Kela, Founder & Chief Investment Officer, Singularity AMC, said, “Most people think of AI in the context of consumer apps. AutoVRse is creating real impact with AI on the assembly line, and that is what our investment thesis is built on. The company operates at the intersection of AI and India's manufacturing revolution. We believe this is how the world will train and operate its industrial workforce over the next 10 years. AutoVRse sits at the edge of a massive, largely untapped market, and we believe the growth from here will be extraordinary.”

Aditya Deshpande, Principal, Lumikai, said, “We're thrilled to deepen our partnership with AutoVRse as they build out cutting-edge AI and VR infrastructure for Fortune 500 enterprises. With VRseBuilder, AutoVRse has demonstrated how immersion, participation and personalisation are finding consequential real-world applications across industrial training in warehouses, labs, plants and field operations of high-precision industries such as pharma, life sciences, manufacturing and petrochemicals, globally. We're excited to back Ashwin, Adarsh and the team as they make immersive AI the operating layer for global industry.”

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European auto major Stellantis and American technology company Factorial Inc. have integrated solid-state battery technology into a Dodge Charger Daytona development vehicle and launched a road-testing programme. The initiative represents the first integration of solid-state cells into a Stellantis vehicle and the first automotive application of the technology in North America.

The development vehicle utilises Factorial's Factorial Electrolyte System Technology (FEST), which combines a lithium-metal anode with a solid polymer separator. In validation testing, the cells demonstrated a specific energy density of 375 watt-hours per kilogram (Wh/kg) and achieved a charging transition from 15 percent to 90 percent state-of-charge in 18 minutes. The cells also verified thermal stability across an operational temperature envelope spanning minus 30 degrees to 45 degrees Celsius.

Integrating the solid-state cells into a production-based car required a modification of the vehicle's battery enclosure. Stellantis designed and implemented a patented mechanical architecture to house the cells within the existing pack layout. Engineers also modified the electronic control systems and pack management software to optimise current distribution while satisfying automotive durability and crash safety regulations.

The newly initiated tracking and calibration programme on public roads will evaluate the performance, structural durability and overall safety of the modified pack under real-world driving and charging cycles. The project is a phase within a multi-stage development agreement between the two entities. Factorial, which recently listed on the Nasdaq exchange following a business combination, develops scalable battery technologies and counts Stellantis, Mercedes-Benz, Hyundai and Kia among its strategic investors.

Ned Curic, Chief Engineering and Technology Officer, Stellantis, said, "Battery development is a balancing act. It’s not enough to optimise a single metric. We need a system that delivers real benefits in a real vehicle. This milestone shows we are bringing solid-state batteries closer to our customers with the potential for longer range, faster charging and lower costs. Just as important, FEST’s strong compatibility with lithium-ion manufacturing processes gives us a critical path to scale this technology.”

Siyu Huang, CEO, Factorial, said, "We are deeply honoured to work alongside Stellantis, one of the world's great mass-market automakers, on this STLA Large-based development car. What we have built together, from cell chemistry to pack architecture to enable real-world road testing, is exactly the kind of deep, full-stack collaboration that solid-state has always required. This milestone doesn't just validate FEST; it sets a new bar for what automotive-grade solid-state batteries can deliver and supports the development of future vehicles designed to meet the evolving needs of drivers."

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German luxury carmaker Mercedes-Benz has officially launched large-scale series production of its new high-performance electric axial flux motor at its Berlin-Marienfelde facility.

Founded in 1902, the company’s oldest active manufacturing site is being transformed into a global centre of excellence for high-performance electric motor fabrication.

The compact, high-power-density drive system is making its commercial production debut on the front and rear axles of the new all-electric Mercedes-AMG GT 4-Door Coupe.

Bringing axial flux technology to automotive mass production required overcoming steep engineering barriers. The manufacturing footprint spans approximately 30,000 square meters across three production halls, utilising seven highly automated assembly lines.

The production workflow comprises 98 distinct process steps, including 65 deployed for the first time by Mercedes-Benz and 35 entirely new to the global manufacturing sector. These industrial innovations have generated more than 30 patent applications.

The axial flux motor, rather than using traditional round wire, uses rectangular copper wire to pack more conductive material into a tight space, boosting power density. Mercedes-Benz co-developed a high-speed bending process to shape the wire at tight radii without pinching, wrinkling or breaking the insulation coating.

The coil ends are connected to adjacent wires via ultra-precise laser welding. This delivers minimal, highly localised thermal input to prevent heat damage to surrounding plastic components.

Furthermore, drivetrain plastic parts undergo simultaneous laser transmission welding. To prevent geometric inaccuracies, an AI-driven optical system tracks component placement in real time, locks virtual protection zones over sensitive areas and verifies seal integrity instantly.

During final assembly, the stator is structurally integrated between two heavy, magnet-loaded rotor discs. The line manages massive magnetic pull forces of up to 9 kN (approx. 900 kg), keeping the stator perfectly balanced within the magnetic centre plane under a tight tolerance of less than 0.1 millimetres using micro-frequency control pulses.

The current motor design builds on early prototype architectures from British electric motor specialist YASA, which became a wholly-owned subsidiary of Mercedes-Benz in 2021.

Michael Schiebe, Member of the Board of Management, Mercedes-Benz Group AG (Production, Quality & Supply Chain), said, “With the start of large‑scale series production of the axial flux motor in Berlin‑Marienfelde, we are bringing a pioneering innovation for electromobility into industrial reality. In doing so, we are sending a strong signal of technological leadership, operational excellence and the transformation of the automotive industry in Germany."

Patrick Schnieder, German Federal Minister of Transport, noted, “Mastering the demanding axial flux technology is a major opportunity for the German and European automotive industry. This innovative electric motor helps establish a strong foothold in the premium segment. The start of production of the axial flux motor in Berlin-Marienfelde sends a powerful signal about Germany’s strength as an industrial location. With Mercedes-Benz’s axial flux motor, electromobility gains additional momentum. A decisive factor in the continued success of e-mobility is the availability of charging infrastructure. Through our Charging Infrastructure Master Plan 2030, we support both the considerable commitment of the charging infrastructure industry and the efforts of the automotive industry.”

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NXP Semiconductors has introduced the SAF8444, an automotive radar system-on-chip designed to enable advanced driver assistance systems (ADAS) processing on the sensor itself.

Manufactured using 28-nanometre RFCMOS technology, the single-chip solution operates across the 76–81 GHz automotive radar band to support short-, medium- and long-range sensing. The chip is intended for vehicle platforms, including electric vehicles, where it reduces system costs by simplifying thermal management and vehicle integration.

The system addresses entry-level and economy vehicle lines by integrating hardware components to lower overall bill-of-materials costs. It combines an Arm Cortex-A53 applications processor, an Arm Cortex-M7 real-time core, and NXP’s proprietary Signal Processing Toolbox radar accelerator with digital signal processor support. This architecture allows perception-level processing to occur directly on the radar sensor, reducing the data-load reliance on centralised vehicle compute resources.

The technology is optimised for standard automated safety functions, including adaptive cruise control, autonomous emergency braking, blind-spot detection and park assist. To meet safety criteria such as the Euro NCAP 2030 requirements, which include low-light pedestrian detection, the chip fuses camera and radar data.

Additionally, it features a dual-threaded accelerator to run anti-jamming algorithms and mitigate radio frequency interference in congested environments.

NXP supports the device with an enablement ecosystem that includes radar software development kits, safety frameworks, security components, power management integrated circuits, and networking solutions.

Meindert van den Beld, Senior Vice-President and General Manager, Radar & ADAS, NXP Semiconductors, said, “SAF8444 strengthens our one-chip radar portfolio with a solution that balances performance, power efficiency, and cost. It allows customers to meet tightening safety requirements while reducing system cost—an essential step toward democratizing ADAS adoption.”

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