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. 

Venkat Rajaram, Cygni Energy, Founder & CEO, along with Vipul and Gautam.

Hyderabad-based Cygni Energy has unveiled Phase I of its fully automated Battery Energy Storage System (BESS) gigafactory at E-Mobility Valley in Maheshwaram, Hyderabad, signalling a major leap in India’s electric vehicle (EV) and clean energy manufacturing landscape. The company is investing INR 2.5 billion over two phases to ramp up capacity from 4.8 GWh to 10.8 GWh over the next 12–24 months.

With a sharp focus on electric mobility, energy storage systems, and next-generation battery chemistries, Cygni is positioning itself to meet growing domestic and international demand for sustainable energy solutions. The company is also actively developing sodium-ion and sulphur-based batteries to complement traditional lithium-ion chemistries, alongside investments in thermal safety, recycling and advanced energy management algorithms tailored to Indian conditions.

Venkat Rajaraman, Founder & CEO, Cygni Energy, said, “In the long term, as part of India’s 100 GWh roadmap, we expect to become self-sufficient in cell manufacturing. We are also seeing a convergence of newer chemistries like sodium and sulphur. Sodium-ion batteries, in particular, are expected to play a critical role in India’s EV journey –given their lower cost of USD 6 per kWh versus USD 24 for lithium. While lithium demand currently exceeds sodium by 3x, India’s early-stage advantage allows us to leapfrog.”

“We cater to three markets – BESS, commercial and industrial storage, and electric vehicles. We have been manufacturing EV battery packs for a long time, earlier from a rental facility and now from our own factory. Today, we have a gigawatt-scale order pipeline for two- and three-wheeler EVs and large-scale storage systems. We’re also working with IIT-Madras' Centre of Battery Engineering and Electric Vehicles (C-BEEV) to co-develop future technologies. EVs contributed nearly 50 percent of our revenue till FY2025.”

The new facility spans 160,000 square feet and is engineered with automated Poka-Yoke-enabled lines and end-to-end traceability for high-quality battery module production. Till date, the company has raised USD 6.4 million in 2018 and USD 12.5 million in 2022 to fund its expansion.

The first phase investment of INR 1 billion supports an initial 4.8 GWh capacity. An additional INR 1.5 billion will be invested to reach 10.8 GWh under Phase II. The company expects to generate INR 26 billion revenue from Phase I, which it aims to double post-expansion.

Cygni’s batteries are designed for EV and grid-scale applications. The company has delivered over 500 MWh of batteries and claims to have a confirmed 1 GWh order pipeline, with growing traction in electric two-wheelers, three-wheelers and small commercial vehicles (SCVs). Most of the 80-plus components in its battery systems – such as busbars, cell holders, thermal and mechanical elements – are now locally sourced, reflecting India’s evolving EV ecosystem.

Jayesh Ranjan, Special Chief Secretary to the Government of Telangana and CEO of the Industry & Investment Cell in the CMO, inaugurated the facility alongside Prof. Ashok Jhunjhunwala, Chairman of IIIT-Hyderabad, and Srini Raju, Founder of iLabs Group.

Jayesh Ranjan, said, “The inauguration of Cygni’s battery manufacturing gigafactory in Telangana marks a transformative step toward sustainable energy, manufacturing excellence, and innovation. This facility not only strengthens India’s commitment to clean energy but also creates jobs, fosters local talent, and builds a robust ecosystem for the future of energy storage solutions.”

Cygni expects to create over 1,000 direct and indirect jobs and is planning additional 2 GWh cell-to-pack automated lines as part of its future roadmap. With government support and rising EV adoption, the company is well-positioned to be a catalyst in India’s energy transition

Chennai-headquartered two-wheeler and three-wheeler major TVS Motor Company has announced its financial results for FY2025. The company reported a record revenue of INR 362.51 billion, up 14 percent YoY, as against INR 317.76 billion a year ago.

The operating EBITDA came at 12.3 percent, while the net profit grew by percent at INR 27.11 billion, as against INR 20.83 billion last year.

During the year the company sold a total of 4.74 million vehicles, up 13 percent, as against 4.19 million vehicles last year. This includes 2.19 million motorcycles and 1.90 million scooters, clocking a growth of 10 percent YoY and 21 percent YoY respectively.

Electric vehicles sales grew by 44 percent to 279,000 units, as against 194,000 units last year. Three-wheeler sales came at 135,000 units, as against 146,000 units last year.

Hindustan Zinc, the world’s largest integrated zinc producer, is marking World Corrosion Awareness Day on 24 April with a nationwide campaign titled #ZungKeKhilaafZinc, aimed at raising awareness about corrosion and promoting zinc galvanisation as a preventive solution.

The company shared that corrosion costs India around 5 percent of its GDP annually –over USD 100 billion – in infrastructure and asset damage. The company’s campaign included social media outreach, public demonstrations and a consumer survey to highlight the economic and structural impact of corrosion.

As part of the initiative, the company undertook a demonstration in Udaipur, where galvanised and non-galvanised two-wheelers were displayed side by side to show the visible difference in corrosion resistance. The initiative targeted general consumers, especially in the automotive and infrastructure sectors.

Arun Misra, CEO, Hindustan Zinc, said, “Corrosion poses a serious threat to our infrastructure and the nation’s economy at large. At Hindustan Zinc, we believe awareness is the first step toward real change. While it’s essential for manufacturers to adopt galvanisation, consumers also play a vital role by asking the right questions – especially when it comes to long-term investments like homes and vehicles. Through #ZungKeKhilaafZinc, we’re committed to educating industries and individuals alike about the critical value of zinc protection.”

India’s climate makes it especially vulnerable to corrosion, but global examples such as Japan and Australia show that losses can be reduced with protective measures. In the automotive industry, galvanised steel is increasingly used in vehicle structures to improve durability and reduce maintenance costs.

Hindustan Zinc had recently introduced EcoZen, a low-carbon zinc product made using renewable energy, and continues to supply to over 40 countries. The company holds about 75 percent of India’s primary zinc market.

Tata Motors, one of India’s leading automobile manufacturers, has joined forces with Tata Power Renewable Energy (TPREL), a subsidiary of Tata Power, for a Power Purchase Agreement (PPA) to co-develop a 131 MW wind-solar hybrid renewable energy project.

The initiative is expected to generate around 300 million units of clean electricity annually and offset over 2 lakh tons of CO2 emissions each year. The strategic move is set to provide a reliable supply of green, cost-effective energy exclusively to Tata Motors’ six manufacturing facilities in Maharashtra and Gujarat, supporting production of both commercial vehicles and passenger vehicles.  

The move is part of Tata Motors’ clean energy transition for achieving its RE-100 commitment ahead of the 2030 target.

Vishal Badshah, Vice President – Operations, Commercial Vehicles, Tata Motors, said, "As a key driver of India’s mobility and logistics ecosystem, Tata Motors Commercial Vehicles is proud to lead by example in sustainable manufacturing. This project reinforces our commitment to integrate renewable energy into our operations and reducing our carbon footprint while meeting our RE-100 goals. It also reflects our broader purpose of delivering mobility solutions that are sustainable at every stage –from production to performance."

Pramod Choudhary, Vice President – Operations, Tata Motors Passenger Vehicles, added, “We are committed to transition to clean energy for building a future ready automotive business. With this PPA our plants in Maharashtra and Gujarat will take a significant leap in our journey towards Green Manufacturing, complementing India’s green transition. It’s a defining step towards making our Passenger Vehicle Operations greener, smarter and more resilient on sustainable basis.”