OEMs are facing new challenges to improve the existing technologies and develop next-generation ones for the new mobility in shorter times. Reducing market responding time along with new complexities are paving the way for virtual simulation, which displaces physical tests and prototypes by virtually replicating product development, testing and manufacturing with simulations. Emmanuel Leroy, Executive Vice-President Industry Solutions at ESI Group, explains, “We enable our customers to drastically reduce every additional physical prototype by using our solutions. In the end, only one physical prototype is required to validate the whole concept. We envision that one day we may be able to virtually certify a product from end to end.” Excerpts:

Q) How did the Covid impact the software and services businesses of ESI Group?

The Covid pandemic has accelerated the need for more digitalisation within the industrial market. It has also somehow accelerated the readiness level of our customers and made solutions such as virtual prototyping even more relevant. Indeed, we enabled the continuity of our clients’ business. The use of virtual prototyping allowed them to continue designing, testing and prototyping their products. Our human-centric approach – one of ESI Group’s four outcome solutions – was particularly used by our customers to ensure the continuity of their businesses: using virtual reality to experience the product from home.

During pandemic times, we also provided our CFD (computational fluid dynamic) solutions to help investigating different scenarios to demonstrate the effect of occupant proximity, ventilation systems and contamination avoidance unique to each office and plant environment. ESI Group developed different virtual scenario, based on its facilities in India, to optimise the return to offices and on plant – especially on a car assembly line.

How the growing complexity of part process is influencing the virtual testing?

We notice that the automotive industry is facing more and more draconian regulations, disruptive technologies, intensifying competitions and shortening response time. Coupled with these, customers are getting more demanding on quality, reliability, safety and production deadlines in the business. Indeed, end users are no longer looking for products but for results (flight hours instead of engines, number of possible kilometres instead of electric car, etc.) and they seek for committed and responsible automakers to motivate their buys. At ESI Group, we have understood these preoccupations and we have defined four primary solutions answering our customers’ expectations.

The first one is the Pre-certification and Validation, enabling gains in performance and productivity. The purpose is double: meeting certification and validation requirements like crash, safety and fatigue issues in the first attempt and then increasing productivity with predictive models and process automation.

The second outcome is Smart Manufacturing, which enables to establish the right manufacturing processes to meet the performance indicators for industrial products and processes.

The Human-Centric Product and Process Validation, our third outcome, focuses on humans by implementing an operator-centric approach to ensure the efficiency of assembly, maintenance operation and the safety of human interactions.

The last one, Pre-experience, is the most advanced solution of ESI Group. Here, our customers and the operators do not look at the product itself, but virtually experience a product, component, subsystem or system under numerous conditions and environments.

Using these approaches, we identify industry challenges from the customer’s perspective and support them in achieving their results.

Finally, as products are getting more complex, one of our strengths is our end-to-end multi-material assembly solution with modelling of different materials (steel, aluminum, composite) and manufacturing processes, covering all the product development cycle.

What will be the growth drivers for the internal combustion engine-driven vehicles business?

Safety is essential and will remain a key driver in the future. Today, the active safety is gaining traction owing to the regulations and overall trends. There is an increasing demand for smart integrated safety, which caters to both active and passive what?

Alongside there are regulations on Co2. In Europe, the Worldwide Harmonised Light Vehicle Test Procedure (WLTP) Norm is challenging and will eventually be implemented in other countries. Regarding Co2 reduction, we focus part of our research and innovation around engine efficiency, aerodynamics and light-weighting, as we did with Bentley for instance.

OEMs are also looking to reduce the manufacturing cost and development time which are leading demand for virtual prototyping, digital twin and shifting OEMs’ investment from hardware to software. The end-to-end value and the digital continuity from the early design to the production is essential to achieve these goals.

OEMs are exploring possibilities to manufacture ICE vehicles and EVs on the same line. Being a solution provider for the smart manufacturing process, how do you see this as a challenge?

Some OEMs assemble EV and ICE vehicles on the same line and look for flexibility, while others use completely dissociated platforms. We, consequently, must find the right strategy regarding their requirements. The new upcoming challenges in CASE mobility manufacturing will bring even more complexities from components to manufacturing. We have to consider the complexity to train the operators: our virtual reality solutions are key here. We help our customers by providing training, on both ICE vehicles and EVs manufacturing processes to their team, even from different place around the world, gathered on the same interface. This solution gathers all stakeholders (from operators to QHSE officers and plant managers) around the same product. This immersive tool helps getting complementary feedbacks early on in the process.

Where do you find more competencies or comfortability — in the complete vehicle design or component design?

Clearly, we are positioning ourselves on the whole vehicle design as it gives the most significant benefit for the OEM and other customers. We are talking about an end-to-end value that we can demonstrate on full scale CAE demonstrators. When it comes to a standalone component, the complex interactions between components and environment are not well taken into account and can lead to reduced predictiveness. In this case, we come up with a holistic view of the problem itself. It is how we defined the four outcome solutions introduced earlier.

Do you think that virtual prototypes will, at a 100 percent, completely replace physical ones ?

Virtual prototypes are step by step replacing physical prototypes. Nevertheless, I think physical prototypes remain today essential to certify the product at the very end of the development phase. To give an example, in 2019 Renault succeeded a 5-star rating of its Clio 5 on the Euro NCAP safety certification test with a single physical prototype, the one needed for the consumer test. Virtual certification is a topic discussed within the automotive ecosystem, allowing to solely relying on the simulation from end to end. But we are not at that point right now.

Which is your largest market for automotive business?

The automotive industry is the most significant contributor to our total revenues. Today, Japan is the largest market for our automotive business. However, India has been an important market for ESI, and it has been growing quite well over the years.

Most of our engineering developments teams, for both our software and our platforms, are based in India.

What are the challenges in the business?

The increasing complexity I mentioned before is definitely a challenge, but it also brings opportunities to us. Our end-to-end multi-material, multiprocess solutions and chaining capabilities are key to overcome the challenges of the automobile market. Due to the ever growing content of electronics, system simulations and systems of systems techniques are improving as well. Our focus is to strengthen our collaboration with partners in the ecosystem to support the customers in solving their complex problems. (MT)

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COEP Technological University (COEP Tech) and JSW Projects, a subsidiary of JSW Group, have signed a Memorandum of Understanding to establish an Advanced Battery Research & Development Centre at COEP Tech's Chikhali Research Park in Pune.

The initiative represents a combined investment of over INR 8 billion to construct an indigenous battery prototyping and pilot-scale research facility on an academic campus in India.

The project is structured in two operational phases – phase 1 will establish a Cell Research & Development Centre focused on the design, simulation and prototyping of lithium-ion and sodium-ion cells.

Phase 2 will expand the site into a Cell Validation Centre with pilot-line capabilities to produce battery cells ranging from 100 Ah to 600 Ah. The facility aims to develop cell chemistry and battery architectures adapted to Indian climatic conditions and operational requirements across electric mobility and stationary grid storage applications.

Sunil Bhirud, Vice Chancellor, COEP Technological University, said, "This collaboration has the potential to create a strong indigenous alternative to imported batteries and make a significant contribution to India's journey towards self-reliance. For students, it will provide a unique opportunity to learn and work on cutting-edge battery technologies. The scale and scope of the Phase I and Phase II collaboration between COEP Technological University and JSW make it a landmark industry-academia initiative. At a time when next-generation battery technologies are receiving significant research attention across the country, the partnership places research, innovation and technology development on a much larger platform. The collaboration has the potential to develop technologies that can reduce dependence on imported batteries and contribute to the vision of a self-reliant and developed India. The scale of this initiative makes it a significant step forward in strengthening India's battery technology ecosystem. We are grateful for the valuable support extended by the Government of Maharashtra and the Board of Governors of COEP Technological University in enabling this important initiative."

Sajjan Jindal, Chairman, JSW Group, said, “Cell is the new oil. Just as oil powered the last century, battery cells will power this one, from electric vehicles to the grid. For decades, India has spent precious forex importing oil. This time, we must build the cutting-edge skills and capabilities to make these cells right here, for a new India. Our partnership with COEP Tech, with its 170-year legacy of engineering excellence, will bring industry and academia together to design, test and validate cells built for Indian conditions, and help shape India's clean energy future.”

The R&D centre is designed to support the energy storage initiatives of JSW Energy and the electric vehicle manufacturing operations of JSW Motors. The facility will also serve as a platform for intellectual property creation, scientific publications, and technical workforce development within Maharashtra's industrial belt.

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German automotive major the BMW Group has received the ‘Global New Energy Vehicle Innovative Technology’ award at the 2026 World New Energy Vehicle Congress (WNEVC) in China.

The company was recognised for its sixth-generation (Gen6) high-voltage battery system, which uses round battery cells with a high-nickel cathode. The BMW Group was the sole non-Chinese automotive manufacturer to receive a technology award at the event.

The Gen6 battery system serves as a component of the company's upcoming ‘Neue Klasse’ vehicle platform, which will be integrated across its electric vehicle lineup. In developing the sixth-generation eDrive technology, the BMW Group filed over 500 patent applications. The battery architecture utilises an 800-volt system, bidirectional charging capability and a cell-to-pack design that integrates cylindrical cells directly into the battery pack without intermediate module structures.

Jochen Goller, Member of the Board of Management, BMW AG responsible for Customer, Brands, Sales, said, “We are very proud to receive this international award for our Gen6 high-voltage battery. It confirms our long-term approach of combining technological innovation with the highest standards of quality and safety and genuine customer relevance. With the Neue Klasse, we are setting new benchmarks in this area.”

Thomas Engelhardt, Senior Vice-President Development High-Voltage Batteries, Charging at the BMW Group, said, “The Gen6 high-voltage battery represents a technological leap across all customer-relevant features. Its innovative, flat design with cylindrical cells paves the way for greater range and faster charging, while maintaining the highest level of safety. As a core technology of the Neue Klasse, it forms the foundation for fully-electric driving pleasure across the entire BMW portfolio.”

The battery system incorporates steel-housed round cells, multi-stage insulation and thermal management features. The energy management functions are directed by the ‘Energy Master’ unit, featuring hardware and software developed in-house by BMW to manage power distribution, vehicle electrical system supply and battery data processing. The Energy Master system provides compatibility with both 400-volt and 800-volt charging infrastructure and allows for the integration of alternative cell chemistries.

The presentation marks the fifth consecutive year and sixth time overall that the BMW Group has received recognition at the World New Energy Vehicle Congress, an annual industry conference bringing together automotive, academic and government representatives to discuss electric vehicle developments.

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Japanese automotive component supplier Toyoda Gosei Co has announced plans to establish a new manufacturing facility in the Bidkin Industrial Area in Maharashtra.

The plant will produce interior and exterior components, including bumpers and instrument panels, alongside safety systems such as airbags and steering wheels and functional components like plastic fuel filler pipes.

It will commence operations in the first half of 2029 to supply Japanese car manufacturers operating in the country, including Toyota Kirloskar Motor, which is constructing a vehicle plant in the same industrial zone.

The development represents Toyoda Gosei’s eighth location in India and will operate as a branch plant under its subsidiary, Toyoda Gosei South India.

The site covers approximately 78,400 square metres of land with a planned building area of 29,200 square metres. Toyoda Gosei plans an investment of approximately INR 5.758 billion (JPY 9.3 billion) for the project, with projected workforce numbers reaching around 570 employees by 2030.

The facility will incorporate equipment including electric injection moulding machines with automated mould-changing systems, a bumper painting booth, automated guided vehicles and rooftop solar panels.

Production processes will integrate Internet of Things technology, digital transformation systems, collaborative robots, and mechanical mechanisms derived from Karakuri design principles.

The expansion comes as product demand in India shifts from compact cars toward sport utility vehicles. Toyoda Gosei intends to utilise the new facility to expand its local development and manufacturing network across the region.

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Pune-headquartered automotive company Kinetic Engineering has announced an investment of approximately INR 570 million to support its capital expenditure requirements and expand its electric two-wheeler segment.

The company shared that it intends to deploy INR 170 million toward CAPEX, while INR 400 million will be directed toward electric vehicle manufacturing and distribution. The capital injection is being executed through the final tranche conversion of 4,451,000 warrants issued to promoters in March 2025.

The investment follows an increase in the company's dealer network and product distribution footprint. Kinetic Engineering has signed letters of intent with over 150 dealers across India, with 60 dealerships operational featuring sales, service and spare parts operations. Promoter shareholding in Kinetic Engineering has increased from 50 percent to 69.27 percent over the past four years.

In its electric two-wheeler business, the company is focusing on its Kinetic DX and DX+ scooter models, which incorporate 3.1 kWh lithium iron phosphate battery packs that deliver a range of up to 132 kilometres under Indian Driving Cycle test conditions.

Ajinkya Firodia, Vice-Chairman and Managing Director, Kinetic Engineering, said, "Kinetic Engineering is entering an exciting phase of growth, with strong momentum across both our automotive components and electric mobility businesses. Our auto-components business is seeing a healthy pipeline of new orders, which will support growth and help us work towards our target of improving EBITDA margins to around 12%. At the same time, the response to our Kinetic DX electric scooter has been encouraging, giving us confidence to expand our presence across markets. With continued investments in capacity, technology and our retail network, we are focused on scaling both businesses and building Kinetic into a leading and enduring player in India’s electric mobility segment."

The company aims to secure a position among the top ten electric vehicle brands in India as industry projections indicate electric two-wheeler market volumes could expand from 1.8 million units to 7 million units by FY2030.

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