Currently, India’s foundry market for automotive components is small (only 10 percent of total foundry market — 10 million of cast iron + aluminium) in comparison to USA’s foundry market, which is at 14 million tonnes per annum, of which 3.3 million is aluminium (24 percent). With an increasing focus on higher performance with better safety and lower emission, this gap is going to shrink in the coming years, anticipates Ajay Kapur, CEO – Aluminium & Power Business, Vedanta Aluminium.

“There is immense scope for Indian aluminium producers to tap into the emerging market in the automotive sector,” said Kapur. Vedanta Aluminium was the first in India to supply PFA (primary foundry alloy) to the domestic auto sector. Before, the launch of PFA by the company, India’s entire PFA demand was being met through imports, even though the country has the world’s second-largest aluminium production capacity. Looking at the potential of the auto market and its import dependency, the company decided to tap into the opportunity and develop indigenous capabilities at its state-of-the-art facilities in Jharsuguda and BALCO to meet that demand. Currently, the company has a PFA casting capacity of 240KT spread across its plants in Odisha and Chhattisgarh.

“Primary aluminium producers develop PFAs which are customised to suit the exact needs of automakers in terms of performance, strength, durability, etc. Significant R&D and technical expertise go into developing PFAs, resulting in excellent metal quality and outstanding castability, which makes these alloys the preferred choice for the automotive industry,” explained Kapur. PFAs are ideal for aluminium alloy wheels, cylinder heads and brakes. The company also anticipates that with an increased focus on reduction of vehicle weight with higher safety performance, automotive parts critical to safety will be made from PFA instead of cast iron to offer higher strength and nearly double absorption of crash energy. “Besides, aluminium PFAs will always have the added advantage of cost-saving on fuel and maintenance,” added Kapur.

Vedanta Aluminium has started steadily supplying PFAs to OEMs and ancillaries in wheel manufacturing in India. “Our proactive move to expand business on this front helped us on-board some of the most reputed equipment manufacturers and auto ancillaries as our clients, and we have received a very positive response from them. Encouraged by that, we will soon look to expand our alloy portfolio for supporting manufacturing of cylinder heads, ABS brakes and certain key applications where traditional materials can easily get substituted with aluminium alloy. We are also exploring prospects of long-term investments by auto ancillaries near our aluminium smelters so that they may leverage cost savings in terms of freight, re-melting and electricity,” said Kapur.

The company, according to him, is well-positioned to cater to the current and emerging needs of the Indian auto sector, offering a broad range of products that find usage across the automotive value chain – from casting to extrusion. “When choosing suppliers for alloys, automotive players should look for companies having high-quality casting facilities, sophisticated R&D facilities and technological prowess for developing customised high-performance alloys for their specific needs, and finally, having robust after-sales technical support; USPs that have earned us the trust of our clients,” he added.

Aluminium is the second most used metal in the world after steel, today, and, according to Kapur, it has the potential to become the most important commercial metal in the future. “Most developed countries have already designated aluminium as a core industry. Aluminium holds strategic importance for the economy as the metal of choice for all kinds of transportation, power, aerospace, defence, building and construction needs. So, given the role it plays in supporting the core sectors meet the Government’s ‘Make in India’ initiative, we expect its application to only expand with time,” said Kapur.

The metal’s usage in the transportation sector has been rapidly increasing as it offers an environment-friendly and cost-effective way to increase performance, boost fuel economy and reduce emissions while maintaining or improving safety and durability. Aluminium is substantially lighter than its counterparts, offering a significant reduction in weight, which has a direct impact on fuel consumption and carbon emissions.

The metal also has a higher strength-to-weight ratio compared to traditional materials that enable it to absorb twice the crash energy of mild steel, ensuring that vehicular performance enhancements do not come at the cost of safety. “Further, nearly 90 percent of all the aluminium used in a vehicle is recycled at the end of its lifecycle. The energy required to recycle aluminium is only five percent of the energy required to produce the metal. With all these advantages, aluminium can play a pivotal role in the changing face of the automotive sector,” said Kapur.

Aluminium alloys are used by the Indian auto industry majorly as alloy wheels. Around 95 percent of two-wheelers include aluminium, averaging at 7kg per bike, taking total consumption of aluminium alloy in this segment to 115KTPA (kilo tons per annum). Whereas, only 20 percent of four-wheelers use aluminium, majorly in high-end models, which max out at 40kg per car. “The crux of the matter is, in India, we are yet to explore more applications of aluminium in the automotive industry akin to our global peers. For example, in developed countries, around 21 PFAs are used in the automotive segment to achieve light-weighting in the form of various auto parts and components. In India, we majorly use PFAs only for manufacturing alloy wheels and to some extent, for cylinder heads. So, there is immense potential for usage of aluminium in other auto parts like engine, suspension, front end carrier, instrument panel support, rear frame, chassis and many more,” said Kapur.

Shortly, the company expands its alloy portfolio for supporting manufacturing of cylinder heads, ABS brakes and certain other applications where currently steel or iron is being used but can be substituted by suitable aluminium alloys to provide additional benefits. As the market for aluminium alloys in automotive segment expands with inclusion of newer applications, Vedanta Aluminium will look for opportunities to leverage its technological expertise and R&D capabilities to develop products customised to the needs of the market. Vedanta Aluminium is also open to collaborating with the downstream industry, to unlock the entire potential of aluminium used in the auto sector and cater to the rapidly evolving aluminium requirements of the Indian automotive industry.

In the Indian automotive market, one of the biggest challenges faced today is the increasing imports of auto components from China and other countries. The size of the auto components imports was USD 17.6 billion in FY19. Asia, the largest source of imports for Indian auto-components, had a share of 61 percent followed by Europe at 29 percent; North America at eight percent; Latin America and Africa at one percent each in FY19. China, with 27 percent, enjoyed the status of the largest exporter in the Indian automotive market.

“The potential of the aluminium industry should be acknowledged and recognised as a core sector with a National Aluminium Policy that will encourage, protect and boost the domestic aluminium industry. The domestic capability needs to be harnessed for critical sectors of national importance like defence, aerospace, aviation, transportation, infrastructure, electrification, housing, etc. We must make the vision of ‘Make in India’ a ground reality in these sectors, leveraging the potential of the entire aluminium value chain, from mining to end usage. Besides enhancing domestic capacity and reducing import dependency and subsequently trade deficit, it will also generate huge employment opportunities in our country which has a deep talent pool that needs to be capitalised for the realisation of our vision of a USD5 trillion economy. We are on the right path, but there is still a long way to go,” said Kapur.

The global economy is swiftly moving towards a cleaner, greener and more sustainable lifestyle. For more than a decade now, concerns about fuel efficiency have encouraged OEMs to replace steel with aluminium in vehicle bodies, doors, trunks, hoods, bumpers, crash boxes, brakes and wheels. With the advent of electric vehicles (EV), OEMs worldwide are focusing on exploring and applying new uses of aluminium. The need for lightweight battery casings and heat exchangers in electric vehicles, combined with autonomous vehicles’ demands for high visibility and structural integrity, is expected to exponentially increase the use of aluminium in cars, trucks and buses from now on. “Using aluminium in EVs has several advantages, foremost amongst which is the distance travelled per charge. Lighter the vehicle, the longer its range. Coming to better battery life, thanks to the metal’s thermal and anticorrosion properties, aluminium is ideal for battery frames. Demand for aluminium will also rise on account of infrastructure for serving EVs since the metal is commonly used as a housing material for EVs charging stations as well. While India is waking up to this future of automobiles, partnerships between different automotive industry bodies/institutions and auto companies for sharing knowledge and expertise will help fast-track development of electric vehicles in the country,” said Kapur. MT

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Adient, a global leader in car seating and Autoliv, a global supplier of car safety systems, have co-developed safety solutions to enhance occupant protection in deeply reclined or ‘zero-gravity’ seating positions. The solution, which is ready for mass production, combines Adient’s new seating concept ‘Z-Guard’ with Autoliv’s safety technology.

The partners stated that zero-gravity seating is seeing an increasing demand in mid-end to high-end vehicles. However, the reclined posture can reduce the effectiveness of safety systems designed for standard upright seating.

Adient’s Z-Guard is based on the principle of Multi-Dimensional Collaborative Protection and integrates constraint and energy-absorbing technologies into a dynamic safety system. Key innovations include:

• Active Cushion Collapse Mechanism: This feature rapidly collapses the seat frame in a crash to absorb energy and adjust posture, reducing spinal impact.
• Adjustable Seat Belt Outlet: This feature adapts to passenger posture and body type, enhancing restraint and minimising risks like shoulder slippage.

Autoliv’s technology complements this with an Integrated Seatbelt System, Dynamic Lumbar Retractor, Pelvic Cushion Airbag and Head Side Airbag. These systems work to protect the head, neck, chest and pelvis.

The Z-Guard concept also allows integration with vehicle driver assistance systems. Using predictive signals, it employs motor-driven seat repositioning to adjust the occupant’s posture before a collision to reduce injury risk. If a crash cannot be detected in time, Z-Guard provides protection through dual pretensioners, cushion buffering and a collapse mechanism to prevent forward movement.

Adient is leading the commercialisation of the Z-Guard, which is scheduled for production in a high-volume model from a major global OEM.

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Alumobility, the association that supports the car industry with lightweighting, will attend the Automotive Circle’s EuroCarBody 2025 conference in Bad Nauheim, Germany, from 14^th October to 16^th October.

The conference will focus on production developments in car design and technology, with emphasis on sustainability and lightweighting.

Alumobility will present a new theoretical technical case study, conducted with a North American OEM. The study shows that converting key vehicle systems from steel to aluminium can reduce the total weight of a crossover battery electric vehicle by 20 percent without increasing vehicle cost or manufacturing complexity.

The results will be shared during a technical presentation led by Alumobility Technical Director Professor Mark White, Vice-President Mario Greco and CAE Lead Vincent Laurent. The session will highlight how aluminium-intensive designs can enable:

• Weight reduction (20 percent of total vehicle weight)
• Same or slightly lower overall cost to manufacture a vehicle
• Lower manufacturing complexity with fewer parts and joints
• Enhanced vehicle performance with fewer resources

The project findings support previous Alumobility studies on the potential of aluminium to support vehicle architectures.

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OPEN Alliance and AUTOSAR have formed a partnership to drive the adoption of Ethernet-based communication in vehicles. The collaboration aims to provide users with higher bandwidth, lower latency, and enhanced scalability between vehicle technologies.

The move seeks to address functional safety and cybersecurity requirements while avoiding duplicated work. The groups will deliver open specifications for Ethernet communication for the global automotive industry, covering areas such as the Physical Layer Specification, Switch configuration and Media Access Control Security (MACsec).

Tobias Belitz, OPEN Alliance Secretary and Renesas Networking Specialist, said, “We are delighted to announce this new collaboration with AUTOSAR. Much like OPEN Alliance, it is a global organisation encompassing leading companies within the automotive and software industry, with a unified mission to develop and establish an optimal networking strategy for modern vehicles. We look forward to working with AUTOSAR to enable greater wide scale adoption of Ethernet-based connectivity.”

Ethernet is becoming the backbone of next-generation vehicles, supporting technologies such as Advanced Driver Assistance Systems (ADAS) and the autonomous vehicle. The partnership will ensure coordination and alignment between the groups’ activities in automotive Ethernet.

Thomas Ruping, Chairperson, AUTOSAR, said, “AUTOSAR warmly welcomes the opportunity to collaborate with OPEN Alliance as an AUTOSAR Attendee. This collaboration strengthens our joint effort to advance Automotive Ethernet and Automotive Ethernet-based technologies, with a particular focus on cybersecurity and safety use cases. In consequence the collaboration will further support the global automotive industry and foster the advancement of automotive software development worldwide.”

Key areas of collaboration include the use of MACsec, which offers a low-latency and high-performance solution for vehicles. The groups will standardise OPEN Alliance specifications within the AUTOSAR framework to ensure the interoperability of Ethernet communication. Features such as Scalable Service-Oriented Middleware over Internet Protocol (SOME/IP), Diagnostics over Internet Protocol (DoIP) and Time Sensitive Networking (TSN) will be mapped.

The collaboration will see joint development of TC11, TC17, TC18 and TC19, which cover Ethernet Switch requirements, MACsec, the Remote Control Protocol and Software for Switch Management.

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The Digital Twin Lab, established by the Automotive Research Association of India (ARAI) with Micelio and IIT Guwahati Tech Park, has now become completely operational.

The lab, supported by the Ministry of Heavy Industries (MHI), enables simulation-led development for electric vehicles (EVs) to help startups, MSMEs and car manufacturers accelerate design, validation and deployment. Its capabilities will be showcased at Micelio’s Global Clean Mobility Summit 2025.

The facility uses a ‘Hub-and-Spoke' model, with the hub at ARAI in Pune and two spokes: one at Micelio Discovery Studio in Bengaluru and the other at the Indian Institute of Technology (IIT) Guwahati. It became fully operational in June 2025.

Dr Reji Mathai, Director, ARAI, said, “ARAI is proud to announce the strategic expansion of its Digital Twinning services across India, extending from the western region to the eastern and southern parts of the country. As India advances towards a future of intelligent and sustainable mobility, ARAI remains committed to empowering OEMs, startups, and automotive innovators with cutting-edge mobility solutions. We are grateful to the Ministry of Industries for their continued support in driving technology-led green mobility initiatives. We also deeply value our collaboration with Micelio, our trusted partner in this endeavour and look forward to a successful journey in broadening ARAI’s national footprint.”

The lab offers digital twin modelling for EV components, including battery packs, motors and drivetrains. It provides virtual validation environments that can simulate conditions such as wear-and-tear and energy consumption. This is supported by Hardware-in-Loop testing systems and AI/ML-based simulation tools.

Shreyas Shibulal, Founder & Director, Micelio Mobility, said, "This lab represents a fundamental shift in how India approaches EV innovation. By providing access to advanced digital twin infrastructure, we are reducing time-to-market and development costs, while also enabling a new generation of Indian EV innovators to compete globally while developing solutions specifically tailored to Indian conditions and requirements."

The facility allows startups and MSMEs to validate their concepts and refine designs without large capital investments.

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