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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India Pistons, the flagship company of Chennai-headquartered Amalgamations Group, has announced the appointment of Suresh KV as Chief Executive Officer effective 14 October 2026.

The appointment marks his return to corporate leadership following a sabbatical of nearly three years spanning from January 2024 to October 2026. Prior to his sabbatical, Suresh served as President of ZF India from June 2015 to December 2023, where he led the vision, strategy, governance, and business performance across 18 manufacturing plants, eight engineering centres, three subsidiaries, and four joint ventures nationwide.

At present, IPL's major OEM customers include Hyundai Motor Company, Maruti Suzuki India, Ashok Leyland, Tata Motors, VE Commercial Vehicles, Simpsons & Co, TAFE, Mahindra & Mahindra and Greaves Cotton, among others.

He also represented the company on the Executive Committee of the Automotive Component Manufacturers Association of India (ACMA), serving as Co-Chair for its Western Chapter.

His earlier tenure at ZF included serving as Executive Director of ZF Wind Power Coimbatore from November 2010 to May 2015. He managed a 60-acre manufacturing facility producing wind turbine gearboxes, axles, and transmissions for agricultural and construction equipment, achieving an annual turnover exceeding INR 9.50 billion in 2015.

Suresh's career in the automotive and industrial manufacturing sectors spans more than three decades, including operational and managerial positions at Hansen Transmissions, High Technology Plastics India, Motherson Sumi Systems, Climate Systems India, Visteon Automotive Systems, Bajaj Auto and Asian Paints.

In his new role at India Pistons in Chennai, Suresh will oversee operations, performance execution, and growth strategy for the manufacturer.

"My nearly three-year break from the corporate world has been much the same – a welcome pause to reflect, rejuvenate and rediscover purpose. This new chapter is much more than professional achievement, alone. It is an opportunity to make a meaningful difference, create lasting value, and perhaps pursue the fifth level of Maslow’s hierarchy of needs – self-actualisation. As the saying goes, 'Old wine in a new bottle' – though I would like to believe that, with age, the wine only gets better! The break is over. The final stint begins, with renewed energy, a clearer sense of purpose, and the excitement of being back in the game," said Suresh KV.

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Japanese automotive companies Honda Motor Co and Mitsubishi Motors Corporation have signed a Memorandum of Understanding (MoU) to develop a Honda pickup truck based on the Mitsubishi Triton.

The agreement marks the first product-supply initiative between the two manufacturers, with the new Honda model scheduled to enter the ASEAN market in 2028. The collaboration originates from a strategic partnership framework established in August 2024 among Honda, Mitsubishi Motors and Nissan Motor, which explores vehicle supply arrangements to expand product lineups across international markets.

As per the agreement, Honda will enter the pickup truck segment in the ASEAN region by utilising Mitsubishi's 1-tonne ladder-frame Triton platform. For Mitsubishi Motors, the OEM supply contract will increase production volumes and vehicle assembly capacity utilisation at its manufacturing facilities in Thailand. The three partner companies continue to examine additional vehicle supply and technology-sharing initiatives.

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Industry leaders at the Renewable Energy India Expo and The Battery Show India (TBSI) highlighted critical mineral access, technology partnerships and domestic manufacturing capabilities to strengthen India's electric vehicle supply chain.

The event convened over 1,080 exhibitors, 1,400 brands and 54,000 professionals, focusing on international collaboration across critical minerals, battery technology and energy storage.

Interestingly, Australia, represented by 20 companies and 32 exhibitors, identified battery production and electric vehicle supply chains as areas for cooperation with Indian manufacturers, leveraging its lithium, cobalt and rare earth reserves. Projections shared at the exhibition indicate India's renewable energy market will reach 486 GW by 2030, while the battery storage sector is projected to surpass USD 8.5 billion by 2031, growing at a compound annual growth rate of 33 percent.

Philip Green, Australia’s High Commissioner to India, said, "The two countries could combine Australia’s engineering expertise and mineral resources with India’s manufacturing strength and integration into global supply chains. Australia produces more than 50 percent of the world’s lithium, according to Green, and holds the world’s second-largest cobalt reserves. It also ranks second or third globally in rare earth resources." he said.

Yogesh Mudras, Managing Director of Informa Markets in India, said, "Renewable energy generation and grid storage needed to expand together as the country advanced its energy transition. India’s renewable energy market is projected to reach 486 GW by 2030, growing at a compound annual growth rate (CAGR) of 15 percent. The country’s battery storage sector is projected to exceed USD 8.5 billion by 2031, with a CAGR of 33 percent."

Anandi Iyer, Director of the Fraunhofer Office in India, said, "India and Germany had opportunities to collaborate in battery research, power electronics, advanced engineering and industrial automation. Approximately 800 GW of renewable energy capacity additions globally in 2025, while global battery storage deployment reached 108 GW, an increase of 40 per cent from the previous year. Technological self-reliance did not mean working in isolation, highlighting the importance of trusted partnerships and supply chains that can translate research into commercially viable solutions."

Manu Srivastav, Additional Chief Secretary in Madhya Pradesh’s Power & Renewable Energy Department, said, "Renewable energy was becoming increasingly competitive with conventional power as costs declined.”  

Jai Asundi, Executive Director of the Centre for Study of Science, Technology & Policy, said, "India would need continued investment in manufacturing, energy storage, grid infrastructure, research and skilled talent to build a resilient clean energy ecosystem."

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Caterham has confirmed its participation in the London International Motor Show 2027, with the British manufacturer set to appear in the event's Built in Britain zone at Excel London from 26 to 28 February 2027. The maker of the legendary Seven, produced in Britain since 1973, will display a selection of its cars on stand 1920.

Visitors will have the opportunity to examine one of the purest driving machines available anywhere, with the Seven widely regarded as a definitive British sports car thanks to its light, simple, hand-built construction in Kent and driver-focused engineering. The Built in Britain zone celebrates the designers, engineers and craftspeople sustaining the country's automotive industry, with specialist sports car makers playing a central role.

Though small in scale, these manufacturers wield enormous influence through cars whose character and focus are admired by major global firms and sought after by enthusiasts. The zone offers them a capital stage before a national audience. The show runs alongside Motorsport Expo and Car Culture UK, with one combined ticket covering all three and around 90,000 visitors expected across the weekend. Friday 26 February serves as the press and trade day, running alongside the public opening.

Stephen Maitland-Oxley, Event Director, London International Motor Show, said, “Caterham is exactly the kind of company Built in Britain was created to celebrate. The Seven is a British icon, and the team behind it has spent more than 50 years proving that lightness, ingenuity and sheer driving fun never go out of fashion. Britain's niche sports car makers are a national asset and we are delighted to give them the spotlight they deserve. Having Caterham with us is a wonderful way to set the tone for the zone.”

Trevor Steel, Senior Vice President – Operations, Caterham Cars, said, “ "At its core, the Caterham Seven is engineered to deliver a driving experience that is as pure, enjoyable and rewarding to the driver, as any car on sale today. Since its inception by Colin Chapman nearly 70 years ago, and since becoming a Caterham in 1973, the Seven has always been proudly built here in Britain, and this is heritage we’re always wishing to celebrate. Built in Britain is a natural home for us, and we are looking forward to meeting enthusiasts, owners and a new generation of drivers in London next February.”

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