Hyundai's Manufacturing Excellence Eased Making All-new i20

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Ganesh Mani

Hyundai Motor India has showcased its Manufacturing Excellence through the origins of the all-new i20, a Masterpiece of Human Centric Engineering. With unassailable standards and processes, the company has created the all-new i20 that is perfected through a prudent use of Industry 4.0 and Automation.

Ganesh Mani S, Director – Production, Hyundai Motor India, said, “Our focus has remained on ensuring supreme levels of manufacturing excellence. This has perfectly culminated in the all-new i20, delivering robust and reliable performance. With our 24-year rich manufacturing heritage of ‘Make in India’, the all-new i20 is yet another benchmark brand from Hyundai that is an edge above the rest.”

THE ROBUST SUPERSTRUCTURE:   

  • Featuring an extensive application of 66 % Advanced & High-Strength Steel, Hyundai has created a Robust Superstructure to enhance crash worthiness and make the car lighter.
  • This super structure is created, using 5,400 Tons Stamping at the Press Shop
  • Incorporating an Online Condition Monitoring systems to monitor machine vibration, Hyundai offers enhanced process quality, changing shapes of metal in elegant curves & creases.  
  • The use of advanced Digital gauge to check the Panel thinning distribution - Crack, Neck Prediction methodology that helps in manufacturing ZERO Crack panels. 
  • Hyundai has used ‘High quality grade coils’ for sculpturing aesthetics and modern look of the all-new i20.
  • Use of 3D scanning of Parts – to analyse and strengthen the press panel parts accuracy and precision

THE IMPECCABLE APPEAL:

  • The all-new i20’s dynamic and futuristic appeal is created at the Body Shop on the Global Body Build Line.
  • Using technology enabled high-quality welding process that features over 450 4th Gen Robots offering 100 % Weld Automation with over 4,000 welding spots in each car, and more than 70 cars being processed every hour
  • Robots on the Line offer a glimpse of the flawless manufacturing process that gives a definitive shape to the origins of the all-new i20.
  • Body shop has three stage advance quality conformation where our quality system is enable with ‘Quality 4.0 techniques’
    • Intelligent weld monitoring
    • Real time weld quality confirmation system [Colour tip sensor]
    • Real time sealer quality confirmation system
  • In house Data scientists in shop floor apply Deep learning techniques for Quality confirmation of Mastic Sealer through Vision Inspection system

 

THE VIBRANT CHARISMA:

 

  • Vivid and striking colours of the all-new i20 are curated at the Paint Shop where High Throw Power 7th Generation Electro Deposition Paint is applied for long lasting Rust Warranty and corrosion resistance.
  • The vibrant charisma of the all-new i20 is processed in seamless automation line that features 72 Robots ensuring the conformity to supreme quality standards and long lasting stylish & glossy looks.  
  • Using an Anode Cell Current Monitoring system, Hyundai has enhanced the paint application quality through an Online Current monitoring method.

THE DYNAMIC PERFORMANCE:

  • Through immense research, hours of design, validation and testing of multiple iterations of operating condition, the all-new i20 has been prepared to offer rip-roaring performance.
  • To give these engines robust performance, Hyundai has employed technologically superior treatment that enhances its performance on road.
  • The in-house Endurance lab tests the performance with load condition for 849 Hours and without load condition for 5 lakhs cycles for transmission systems, and over 350 hours for the Engine system, to ensure enhanced durability
  • Hyundai also employs a Cold Test Bed that is an eco-friendly way of testing the engines over 15 parameters, without burning fuel. It is a fully automated system in which 100% of the produced engines are tested before assembling in vehicles.
  • At the Powertrain Shop, Hyundai manufactures both diesel & petrol engines using 700 CNC Machines with Integrated SPC (Statistical Process Control).
  • With High Speed Vision (60 frames/ minute) 58 Engine parts are verified, offering robust Quality for a Pleasurable Driving Experience.

THE PARADIGM OF QUALITY:

  • To drive enhanced convenience and confidence, Hyundai’s assembly lines are ready to convert robust shells into fully functioning cars in the Assembly Shop.
  • Here 80% of the car’s parts are fixed, preparing it through a 100% systemized 3 stage dynamic tightening confirmation that features:
    • Electric tool tightening 700+ dynamic joints per car (safety and critical parts)
    • Re-confirmation system across all the line (Trim, Chassis and Final line)
    • Tightening quality and Sign-off interlock to ensure zero defect vehicle rollout
  • Additionally, systemized part feeding method is used for maintaining quality in feeding and assembly operation using:
    • Global Part Traceability Information System
    • Advanced Part Management System
    • Mobility Sequence Feeding System
    • Trolley Scheduling System
  • Through a 324-point check in HIDIS (Hyundai Integrated Digital Inspection System), Hyundai is ensuring the highest levels of conformation to quality standards.   
  • Each and every vehicle that rolls of the assembly line - right from the stage of panel press to complete vehicle roll out is thoroughly inspected by over 500 quality in-charge experts.
  • Vehicle final inspection method is digitally enabled for assembled part specification/ type verification.
  • The all-new i20 then undergoes a dynamic road test on 18 drive tracks for various road driving conditions as well as a unique leak test that is equivalent to driving through rain/water pressure that exceeds the heaviest recorded monsoons, with a shower condition of 60mm per minute or 3,600mm per hour at a pressure of 3bar.

The all-new i20 has been developed to create a Masterpiece of Human Centric Engineering that encompasses Human, Machine and Emotions, offering Quality Time to its Valued Customers.

Wayve, NVIDIA, And Stellantis Collaborate To Develop Autonomous Vehicle Ecosystem In France

Stellantis - Wavye - NVIDIA

Wayve, NVIDIA and Stellantis have announced a joint collaboration alongside the French government at the Assises du Véhicule Autonome to support the deployment of autonomous vehicles in France and across the European Union.

The initiative combines Stellantis’ L4-Ready Platforms with the Wayve AI Driver system, integrating NVIDIA Halos OS on the NVIDIA Hyperion compute and sensor architecture. The collaboration aims to establish an autonomous vehicle value chain in France, spanning silicon development, software integration and vehicle manufacturing.

Local transport partners will engage with trade unions, municipal authorities, and mobility stakeholders to address regulatory alignment, safety requirements, and operational deployment.

Philippe Tabarot, French Minister of Transports, said, "I am pleased to see this collaboration between Wayve, NVIDIA and Stellantis launched at the Autonomous Vehicle Forum in France. France is committed to adapting its regulatory framework to accelerate the development of autonomous vehicles while maintaining strict safety and data sovereignty requirements. By bringing together trade unions, city authorities, and mobility stakeholders, this collaboration embodies the collaborative spirit of the Assises du Véhicule Autonome, as well as the approach required to transition from trials to real-world deployment."

Kaity Fischer, VP Autonomous Mobility & Operations, Wayve, said, "France is leading the way in preparing for autonomous vehicles, and we’re proud to enter this collaboration at such an important moment. By working directly with the French Government and our partners, we can help shape how this technology is deployed safely and responsibly and accelerate its development across the country and entire EU."

Anne Laliron, SVP of Technology Research, Stellantis, said, "This collaboration will help accelerate the delivery of autonomous driving technologies that make mobility safer and more convenient for customers. While its impact is global, France is one of Stellantis’ key centres for engineering and technology development, making it a natural home for advancing the future of AI-powered mobility."

Ali Kani, VP of Automotive, NVIDIA, said, "Bringing safe autonomous mobility to Europe requires deep collaboration across AI, computing and vehicle engineering. NVIDIA Hyperion platform, combined with Wayve’s embodied AI and Stellantis’ automotive expertise, provides a foundation for that ambition. Together with the French Government and local partners, we can help build an ecosystem that brings the benefits of autonomous driving to communities across France and Europe."

Audi Debuts Curved Digital OLED Lighting Technology On New Q91

Audi Q91

German luxury carmaker Audi has introduced third-generation digital OLED rear lighting technology on the Q91, marking the production debut of three-dimensionally curved digital OLED panels in the automotive industry.

The lighting system incorporates carrier glass measuring 0.1 millimetres in thickness, allowing a bend radius of up to 200 millimetres to match the vehicle's body contours. The Q91 uses six digital OLED panels housing 512 individual segments, including an outer curved panel with 99 segments.

The curved positioning extends light visibility to wider lateral angles and incorporates warning symbols within the communication light system to alert surrounding traffic to breakdowns, emergency braking or accidents. Up to eight digital light signatures are available across static, active and semi-active display settings.

The vehicle also features digital Matrix LED headlights utilising a 13-millimetre micro-LED module containing 25,600 individual micro-LEDs. The headlight system projects high-resolution lane lighting, orientation paths and dynamic turn signal graphics directly onto the road surface to assist lane centring and indicate directional changes to pedestrians and other vehicles.

Audi first introduced OLED technology on the TT RS in 2016, followed by segmented digital OLEDs on the Q5 in 2020 and second-generation panels on the Q6 e-tron in 2024.

Stefan Berlitz, Head of Lighting Development at AUDI AG, said, "At Audi, light means safety first and foremost – seeing and being seen. Digitalisation opens up entirely new possibilities for further enhancing road safety. The curved digital OLED technology in the Audi Q91 impressively demonstrates this technology’s potential. It combines design freedom, personalization, and communication with the vehicle’s surroundings at a new level. Our vision is to gradually transform light into an intelligent means of communication that makes interaction between the vehicle and its surroundings even safer and more intuitive."

Bolt Selects NVIDIA To Power European Autonomous Ride-Hailing Fleet

Bolt - NVIDIA - Lucid

European ride-hailing platform Bolt has selected the NVIDIA Alpamayo Stack autonomous driving software to operate its vehicle fleet in Europe, starting with Lucid automobiles.

The deployment commences in Madrid in 2027, with subsequent deployment planned in Germany and France. The initiative supports the integration of at least 25,000 Level 4-ready Lucid vehicles equipped with NVIDIA Hyperion compute and sensor architecture. The program contributes to Bolt's objective of deploying 100,000 autonomous vehicles across Europe and the UNECE region by 2035. The system integrates reasoning artificial intelligence with perception and planning modules alongside NVIDIA Halos safety controls.

Jevgeni Kabanov, President and Head of Autonomous Driving, Bolt, said, “Autonomous driving will change how people move around cities, and Europe should play a major role in how that future is built. Our ambition isn't to bring autonomous driving to just a handful of cities. We want to make autonomous ride-hailing available at scale across Europe, with 100,000 vehicles on our platform by 2035. We're bringing together some of the best technologies in the world to make that possible. Following our first autonomous mobility launch in Luxembourg, our next step with NVIDIA and Lucid is to begin a programme in Madrid in 2027. The Region of Madrid is pioneering a structured framework for commercial autonomous mobility in coordination with national authorities. Germany will also be a priority for what comes next, with cities already setting out clear ambitions for autonomous mobility.”

Rishi Dhall, Vice-President of Automotive, NVIDIA, said, “Robotaxis will scale when every vehicle is built on a common, safety-engineered foundation. NVIDIA Hyperion standardises the compute and sensor architecture across vehicle platforms, while NVIDIA Alpamayo Stack and Halos provide the driving intelligence and safety foundation. Bolt’s European platform, operational experience and work with cities and regulators make it a strong partner to bring autonomous ride-hailing to market at scale in Europe.”

Valeo Collaborates With NVIDIA To Develop Autonomous Driving Compute Platforms

Valeo - NVIDIA

French tier 1 supplier Valeo has announced plans to develop and industrialise high-performance compute platforms utilising the NVIDIA Hyperion reference architecture and NVIDIA Halos safety system.

The initiative combines Valeo's vehicle integration capabilities with centralised computing architectures to support software-defined mobility systems. The platform utilises the NVIDIA DRIVE AGX Thor architecture to deliver processing performance and redundancy for Level 4 autonomous driving, commercial trucking and robotaxi applications. The development framework enables automakers to integrate features and deploy autonomous technologies across vehicle models.

Marc Vrecko, Chief Executive Officer, Valeo Brain Division, said, "Our work with NVIDIA marks a significant milestone in our mission to make autonomous driving a safe, scalable reality. By seamlessly integrating NVIDIA’s advanced compute power into our next-generation platforms, we are delivering the flexible, centralised intelligence vehicle manufacturers require to redefine the driving experience and meet the evolving demands of tomorrow’s intelligent vehicles."

Rishi Dhall, Vice-President of Automotive, NVIDIA, said, "Valeo’s expertise in high-performance computing, vehicle integration and automotive-scale industrialisation will help automakers adopt NVIDIA Hyperion and NVIDIA Halos at production scale. Together, NVIDIA and Valeo are providing the AI performance, functional safety and scalability needed to accelerate the development of Level 4 autonomous vehicles and robotaxis."