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 4^th 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 7^th 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.

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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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