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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Bengaluru-headquartered electric two-wheeler manufacturer Ultraviolette Automotive has announced a 5-year investment plan to expand its manufacturing operations in Karnataka.

The company signed a Memorandum of Understanding (MoU) with the Government of Karnataka during the ‘Invest Karnataka’ Conclave in Bengaluru, securing proposed incentive support through the Production-Linked Incentive (PLI) scheme.

The EV maker has announced a two-phase expansion strategy to increase domestic production and support global export requirements:

Phase 1: An investment of INR 2 billion to enhance existing capacity and manufacturing at the current Bengaluru facility.

Phase 2: The establishment of a new production plant in Karnataka with an annual capacity of 150,000 units.

The plan aims to deepen local manufacturing, create employment and accelerate research and development within the electric vehicle sector. Ultraviolette currently produces the F77 performance motorcycle and the X-47 Crossover, utilising proprietary battery technology.

Headquartered in Bengaluru, Ultraviolette intends to expand its Indian retail presence from 40 to 100 cities by the end of 2026. Internationally, the company has entered 12 European countries and has scheduled further expansion into Asian and Latin American markets.

Narayan Subramaniam, CEO and Co-Founder, Ultraviolette Automotive, said, “Karnataka has been central to Ultraviolette’s vision of Making in India for the World. This proposed manufacturing expansion reflects our confidence in the state’s forward-looking EV ecosystem, talent, and policy support. The combination of infrastructure readiness, proactive governance, and long-term incentive visibility creates a strong foundation for Ultraviolette’s next phase of growth.”

Niraj Rajmohan, CTO and Co-Founder, Ultraviolette Automotive, added, “Karnataka has been home to Ultraviolette’s R&D journey from the very beginning. The state offers a unique combination of deep engineering talent, strong supplier networks, and close proximity to key industrial and manufacturing hubs. What makes this especially meaningful for us is that we have built world-class products here proving that with the right talent, ambition, and ecosystem, innovation can be created right here in Karnataka.”

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Octillion Power Systems has announced that its India division has manufactured its 100,000th electric vehicle (EV) battery system. The milestone unit was produced on 20 March 2025 at the company’s ‘Pune Two’ facility for a passenger SUV developed by an Indian automotive manufacturer.

Since commencing Indian operations in 2017, Octillion has expanded from a single facility in Pune to three manufacturing sites across Pune and Gujarat. The company currently operates over 300,000 square feet of production space.

At present, the company’s annual energy production is expected to reach 8 GWh by 2026. The division supplies battery systems for passenger cars, trucks, buses and two-wheelers and three-wheelers. The company recently announced the build-out of its third major facility in Halol, Gujarat, to support a domestic supply chain and mass-scale quality control.

Paul Beach, Global President, Octillion, said, “Reaching 100,000 units made in India is a testament to the hard work and dedication of our entire team. This milestone reflects the trust our clients place in us to deliver safe, durable, and innovative batteries on time replete with exceptional value. Our position is strengthened as we expand in India and continue driving forward: product innovation, market growth and a more resilient supply chain.”

Nikhil Parchure, Senior Vice-President, Octillion, commented, “Our ambition in India is to enable cleaner, more sustainable transportation to help combat the pollution affecting our cities and communities. Reaching 100,000 packs is proof of our India team’s extraordinary dedication to this mission. We deeply appreciate our customers’ trust and we take pride in knowing that vehicles powered by Octillion batteries reflect the ingenuity and excellence of India.”

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Tsuyo Manufacturing has received Single Window Clearance from the Government of Karnataka to establish a 20-acre electric vehicle (EV) powertrain manufacturing and validation facility in the Hubli-Dharwad region. The project follows a Letter of Intent (LoI) signed during the Bengaluru Tech Summit in November 2025.

The company will invest INR 2.5 billion to develop an integrated campus for the development, production and validation of EV powertrain technologies. The facility will house assembly lines and laboratories for electric traction motors, motor controllers, power electronics and drivetrain systems.

The site will also include a dedicated open test track specifically designed for commercial-vehicle powertrain validation.

The project will be executed in two distinct phases to scale voltage and power capabilities:

• Phase 1: Focuses on powertrain platforms up to 250 kW with voltage architectures up to 650V.
• Phase 2: Expands capacity to develop powertrains up to 1100 kW with high-voltage architectures reaching 850V DC.

This infrastructure is intended to serve a range of sectors, including three-wheelers, passenger vehicles, commercial vehicles and industrial mobility.

The initiative is expected to create over 500 engineering and technical jobs over the next three years. It aims to support the growth of a localised EV component supply chain in India, reducing reliance on imports for motor design and power electronics engineering.

Vijay Kumar, Founder & CEO, said, “The Hubli–Dharwad facility will be a significant breakthrough in Tsuyo’s mission to build a globally competitive EV powertrain ecosystem from India. With advanced manufacturing, integrated validation infrastructure, and system-level engineering capabilities, this investment will enable us to deliver high-power, high-voltage electric powertrain solutions for both domestic and international markets. Our focus is to develop and manufacture complete electric powertrain systems with world-class engineering and validation capabilities. The new facility will allow Tsuyo to accelerate innovation in motors, power electronics, and integrated drivetrain solutions while meeting the reliability and performance standards required by Indian as well as global OEMs.”

Lalit Baid, Founder & COO, commented, “The facility will be developed in two phases to progressively scale our integrated EV powertrain technology capabilities. Phase 1 will support powertrain platforms of up to 250 kW with voltage architectures up to 650V, while Phase 2 will expand our capabilities to develop powertrains of up to 1100 kW with high-voltage architectures reaching 850V DC. Importantly, the project will also create over 500 jobs, reinforcing our pledge to building advanced EV technologies and strengthening India’s domestic electric mobility ecosystem.”

Vikas Verma, Partner at Avaana Capital, added, “From the outset, what stood out to us about Tsuyo was the team’s rare combination of deep engineering capability, product innovation, disciplined execution, and focus on localized manufacturing to build globally competitive EV powertrain technologies from India. The approval of this facility is a testament to Tsuyo’s rapid progress and its strong trajectory in scaling both manufacturing and technological capabilities. Their continued progress in building advanced EV powertrain solutions in India is closely aligned with our conviction in the long-term potential of the country’s electric mobility ecosystem.”

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Hindustan Zinc has introduced ‘Tejaswini’, a section led by women across all shifts at its Chanderiya Smelting Complex. The initiative begins with a team of 30 professionals who will manage operations, maintenance and safety within the Leaching and Purification units. This section is a part of the facility’s hydrometallurgy operations, which determine production throughput and quality.

Women now represent 26.3 percent of the workforce at Hindustan Zinc. The ‘Tejaswini’ team is led by Tanya Singh, Plant Manager for L&P I, Hydro. The company has previously introduced an underground all-women mine rescue team and enabled women to lead night shifts and tele-remote mining operations. These actions form part of the Vedanta Group goal to reach 35 percent women representation across its total workforce.

To support the expansion of women in core manufacturing roles, the company has implemented infrastructure updates at the site. These include the V-Safe app, CCTV surveillance, biometric access and dedicated transportation facilities for night shifts. The Chanderiya Smelting Complex is among the largest zinc smelting facilities globally, producing metal for infrastructure and energy sectors.

Arun Misra, CEO and Whole-Time Director, Hindustan Zinc, said, “At Hindustan Zinc, we believe the future of mining will be driven by diverse talent, advanced technology, and a culture of inclusion. The launch of Tejaswini reflects our commitment to creating meaningful opportunities for women in core operational roles that power industrial performance. By enabling women to lead critical processes at our smelting operations, we are strengthening our talent pipeline while demonstrating that leadership and capability transcend traditional industry boundaries. As we pursue our long-term growth ambitions, initiatives like these will help shape a more progressive and future-ready mining sector.”

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