The narrower, bigger diameter tyres of electric vehicles are encouraging innovation around them. Supporting lower rolling resistance, the tyres are pushing suppliers and OEMs to explore new technological innovations. A leading German auto supplier for example has developed a ‘mechanical’ technology to ensure superior manoeuvring with near 180 degrees turn of the steered wheels. 
This is a development that could be applied to ICE rear-wheel drive vehicles as well. Even, light-duty commercial vehicles such as the Tata Ace/1000 or the Switch Iev3/Iev4 that are aimed at the last mile delivery segment were backing up into a tight parking spot or navigating through a narrow lane is part of the job. 
As designers and engineers toy with the idea of larger wheel wells and the ability of the steered – front – wheels to turn as much as 180 degrees, the use of narrower, bigger diameter tyres with low rolling resistance in electric vehicles is spurring yet another round of innovation, albeit as a part of the entire platform architecture that is rather software driven and subject to much virtual development in the interest of ‘time-to-market’ and a differentiated user experience. 
With over 14 million small electric vehicles sold in 2023 the world over, the push has been to develop tyres that enhance operation and performance. Provide a typical ‘family’ car the ability to transform into a sports car given the wave of high torque available from the word ‘go’ in an electric vehicle. 
With electric vehicle sales poised to increase 17.5 percent year-on-year globally to bridge 41.2 million units in 2029, electric vehicle tyres are expected to facilitate a further drop in rolling resistance while employing sustainable raw materials, technologies and manufacturing processes. 
A sustainable EV tire design should consider the whole lifecycle of the product. Tires can be composed of well over 100 different raw materials. These are mixed and the rubber compounds are machined resulting is several components of the tire construction. EV tires are expected to be stronger and lighter, with less rolling resistance due to its importance in CO2 emissions and fuel consumption. 
A key challenge being the development of tyre formulations for electric vehicles with the tread compound that is more resistant to abrasion, it is the instant torque availability that is necessitating tyres that may look like ICE vehicle tyres but are quite different in the way they handle traction and aid a longer drive range. There is the issue of kerb weight as well, not to overlook the new environmental pressures for durability and abrasion resistance. 
Interestingly, new opportunities are being created on the vehicle engineering and dynamics side as well as on the side of electric vehicle tyre development and manufacture. 
Starting with materials that are broadly classified as ‘renewable’ (can be sustained on time) and as ‘recycled’ (re-used and made from recovered end-of-life tyres), it is the tandem mixers that are producing more homogeneous rubber compounds, including tread compounds that employ optimised silica fillers.
Tyres for electric vehicles are demanding the use of triple or quadruple extruders for treads and sidewalls as per the vehicle weight, application and dynamics. Roller head or roller die units are also being used to produce inner liners as a single or multilayer sheet
In terms of textile coating of steel cord components in e-vehicle tyres, four-roll and Z-type calendars are used. Also, full tyre assembly machines that can produce tyres to tighter tolerances, higher specs such as superior uniformity and sans operator invention. 
With electric vehicle tyres and ICE vehicle tyres being tested and validated differently primarily because of the higher load bearing capacity and low rolling resistance, electric vehicle tyres are made up of a different (softer) rubber compound than regular tyres with an eye on less noise, mentioned a testing expert at an OEM that is increasingly producing electric vehicles in India. 
Pointing at an electric passenger vehicle the company launched in India recently, he averred, “Softer compounds are used to ensure less rolling noise and better transmission of torque from the motors to the road.” 
With finer tolerances in need, optical machine vision systems for end-of-line quality inspections, including new technologies such as X-rays to check steel belts, cords and bead reinforcement are increasingly used. 
They are used to check for air bubbles in inner liners as well. Advances in tyre design and manufacture include new developments in simulation software to model the performance of new designs quickly. This is without material input cots. 
AI is being increasingly used to ensure superior analysis. AI is also used to automate manufacturing process as part of Industry 4.0 workflows. 

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Chennai-headquartered commercial vehicle major Ashok Leyland, the Hinduja Group flagship, has commenced construction of a greenfield battery pack manufacturing plant at Pillaipakkam, Tamil Nadu. The project involves an investment of INR 4-5 billion, forming part of a broader investment plan outlined in a memorandum of understanding signed in September 2025.

The facility aligns with the Tamil Nadu Electric Vehicle Policy 2023 and the National Mission on Transformative Mobility and Battery Storage. The project is intended to localise the production of battery packs for the commercial vehicle sector and reduce reliance on imported components.

The Pillaipakkam site marks Ashok Leyland's tenth manufacturing presence in Tamil Nadu. The company aims to use the facility to strengthen the domestic supply chain for its electric vehicle (EV) portfolio and its subsidiary, Switch Mobility.

Ashok Leyland has invested over INR 90 billion in Tamil Nadu since 1948. The new plant is expected to create jobs in high-technology manufacturing and advanced skill development. The foundation plaque was unveiled by M.K. Stalin, Chief Minister of Tamil Nadu, in the presence of state officials and company leadership.

Dheeraj Hinduja, Executive Chairman, Ashok Leyland, said, “Our journey has been closely intertwined with the growth of Tamil Nadu for more than seven decades. Ashok Leyland, along with its subsidiary, Switch Mobility, have already developed a vast range of electric Commercial Vehicles, and have taken a lead position in the EV market. The groundbreaking of the new battery pack manufacturing facility marks an important step in our electric mobility journey and reinforces our commitment to building a strong domestic EV ecosystem.”

Shenu Agarwal, MD & CEO, Ashok Leyland, added, “Battery pack technology is central to the future of electric mobility and energy storage. This facility will enable us to build advanced battery pack solutions with greater efficiency, safety and reliability while supporting the battery supply chain localisation It will also contribute to developing specialized talent and creating new opportunities in high-technology manufacturing within Tamil Nadu.”

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Swiss technology major ABB has announced that it is set to further invest around USD 75 million in India for 2026. The capital expenditure is directed at expanding the company’s manufacturing footprint and research and development (R&D) capabilities across five locations: Bengaluru, Hyderabad, Nashik and Vadodara.

This move follows a USD 35 million investment in 2025 and forms part of ABB’s ‘local-for-local’ strategy. Currently, 85 percent of the products ABB sells in India are manufactured within the country. The expansion is expected to create 300 skilled jobs in engineering, research, and operations.

The investment is distributed across several key hubs to support electrification, motion, and automation:

• Nelamangala, Bengaluru (USD 14 million): Expansion of Campus 1 and 2 to scale converter manufacturing for high-speed rail and metro segments. It includes a tenfold increase in production for uninterruptable power supply (UPS) solutions.
• Peenya, Bengaluru (USD 21 million): Funding to increase capacity for low-voltage drives and specialised motors, including flameproof and smoke-venting variants. The site will add an innovation lab and remote monitoring facilities.
• Nashik (USD 22 million): Expansion of the circuit breaker factory and the Vacuum Interrupter (VI) facility. This site will drive the localisation of 33kV Primary Gas Insulated Switchgear and SF6-free technologies by 2028.
• Hyderabad (USD 12 million): Completion of phase one of a new R&D and engineering hub, including a high-power testing laboratory.
• Vadodara (USD 6 million): Scaling of the synchronous generator and induction motor factories to serve the metals, oil and gas and wind sectors.

ABB’s revenue in India reached more than USD 1.5 billion in 2025, representing roughly 4 percent of the Group’s global total. The company identified grid modernisation, data centre development and renewable energy transition as the primary drivers for the increased capacity.

Morten Wierod, Chief Executive Officer, ABB, said, “This investment in India is an important part of our strategy to support infrastructure build-out and growth in one of our fastest growing markets. We are seeing strong demand driven by the country’s energy transition, grid modernization, data center development, and the rapid expansion of the metro and high-speed rail segments. Our expanded facilities will ensure we meet this demand while enhancing our capabilities to serve other markets in the region.”

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American technology company Aptiv has announced that its Board of Directors has approved the spin-off of its Electrical Distribution Systems business into a new publicly traded entity – Versigent.

Versigent provides signal, power and data distribution systems for the automotive and commercial vehicle sectors. It operates engineering centres across four continents and manufacturing facilities in more than 30 countries, focusing on low-voltage and high-voltage electrical architectures.

The separation will be executed through a distribution of Versigent ordinary shares to Aptiv shareholders. Stockholders will receive one ordinary share of Versigent for every three ordinary shares of Aptiv held as of the record date.

Aptiv shareholders are not required to take action, pay consideration, or exchange existing shares to receive the Versigent stock.

Following the separation, Aptiv will continue its operations as an industrial technology company focused on vehicle automation, electrification and digitalisation. Versigent will maintain its legacy in designing and manufacturing advanced vehicle architectures for original equipment manufacturers (OEMs).

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Honeywell has announced that its AI-powered Battery Manufacturing Excellence Platform (Battery MXP) is being integrated into the Alabama Mobility and Power (AMP) Center’s research lab at the University of Alabama. The platform is designed to automate battery production, improve cell yields and accelerate the startup of manufacturing facilities.

The AMP Center serves as a research hub for mobility and power technologies, including electric vehicle charging infrastructure and energy storage systems. The Honeywell platform will be used as the automation standard to train engineers and battery professionals in scaling production for industrial requirements.

Honeywell is also collaborating with FOM Technologies at the AMP Center to focus on the electrode production process. This phase of manufacturing is identified as a significant challenge in battery assembly; the partnership aims to use Battery MXP to automate this stage and improve the safety of cells for original equipment manufacturers (OEMs).

Key objectives of the integration include – workforce development, operational excellence and industry access.

The lab is scheduled to open in the second quarter of 2026. The deployment is intended to support the automotive industry while addressing energy requirements for data centres, grid stability, and regional electrification goals.

Mike Oatridge, Executive Director of the Alabama Mobility and Power Center, said, “The AMP Center was created to connect industry, academia, and state initiatives around the future of mobility and power. The deployment of Battery MXP supports Alabama’s automotive industry while advancing solutions for data center growth, grid stability, and the state’s long-term electrification and economic development goals.”

Russ Ford, President, Honeywell Process Automation Solutions, stated, “The rapid evolution of battery technology calls for a skilled workforce and advanced production capabilities at large scale, including comprehensive automation platforms powered by AI. AMP’s use of Battery MXP is poised to be a catalyst to empower the next generation of engineers in this important industry as it continues to grow.”

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