Motion plastics manufacturer, Igus India expanded its footprint in the country by inaugurating a new manufacturing plant spanning 92,000 square feet in Bengaluru Thursday. 

The state-of-the-art plant in Mandur near Budigere in Bengaluru comes at a point when the company prepares to focus on new divisions dedicated to the semi-conductor and renewable energy sectors, areas poised for substantial growth. The expansion is part of Igus’s long-term strategy to enhance its operational capabilities and support its extensive customer base in India.

The newly inaugurated facility is a testament to the company’s long-term commitment to India, involving an investment of over INR 1 billion. This financial outlay reflects the company’s dedication to maintaining its competitive edge through innovation and cutting-edge technology. 

Of the total investment, INR 200 million have been allocated for setting up the factory, INR 400 million for advanced injection moulding machines and INR 200 million for enhancing the manufacturing process. The plant’s infrastructure is designed to meet the high standards of motion plastics production, ensuring that Igus India continues to deliver world-class products tailored to the unique demands of the Indian market.

Since its establishment as a wholly-owned subsidiary in 2000, Igus India has become a prominent player in the motion plastics industry, catering to over 19,000 customers across the country. The company’s extensive product catalogue boasts 125,000 parts, which are used in a variety of customer-driven assemblies, many of which are customized and assembled locally. This vast array of products underscores Igus’s commitment to innovation and customer satisfaction, with over 200 new products introduced annually. The company’s ability to adapt to the evolving needs of its customers has been a key driver of its success in the competitive Indian market.

Looking ahead, Igus India has ambitious plans to further strengthen its operational capabilities and market presence. The company is eyeing significant revenue growth, with expectations of reaching INR 3.4 billion in revenue this year. To support this growth and enhance its logistical efficiency, Igus India plans to establish new logistics and assembly centres in Pune, Gurugram and Noida. These new facilities will enable Igus to better serve its customers across India, reducing lead times and improving overall service delivery.

The focus on emerging industries like semi-conductors and renewable energy is a strategic move by Igus India to align itself with sectors that are poised for substantial growth in the coming years. As India continues to invest in its semi-conductor manufacturing capabilities and renewable energy infrastructure, the demand for high-quality motion plastics is expected to rise. Igus India’s expansion positions the company to capitalise on these opportunities, offering innovative solutions that meet the specific needs of these rapidly growing industries.

The opening of the new manufacturing facility in Bengaluru marks a significant milestone for Igus India, reinforcing its position as a leader in the motion plastics industry. With a strong commitment to innovation, customer satisfaction and market expansion, Igus India is well-positioned to achieve its growth objectives and continue delivering value to its customers across the country. 

Emphasising the strategic importance of this expansion, Igus India Managing Director Deepak Paul stated, “The Indian market presents tremendous potential for Igus as demonstrated by our continued growth and investment here. Our objective is to deliver cutting-edge products and solutions not only to our customers in India but also on a global scale. Igus’s global focus on cost-sensitive and sustainable solutions, encapsulated in our motto ‘Tech up, cost down,’ is perfectly aligned with the Indian approach to technology and innovation. This alignment has been a key driver of our significant growth in the country. As we look forward, our plans include expanding beyond Bengaluru, with logistics and assembly centres set to be established in Pune, Gurugram, and Noida.”

 Igus India is currently the 6th largest subsidiary among Igus’s 38 global subsidiaries, a position that reflects its strong performance and growth potential. Over the past two years, Igus India has doubled its market growth, with revenue figures climbing from INR 1.99 billion to INR 3.13 billion. The company expects this upward trajectory to continue. Additionally, Igus India has invested in a clean room testing facility in Germany and plans to establish a similar setup in India, further enhancing its product development and quality assurance capabilities.

Commenting on the occasion, Country Manager and Director Santhosh Jacob said, “Technology and innovation are at the core of everything we do at Igus. With a catalogue of 125,000 parts and 247 new products introduced this year, we are constantly inspired by our customers’ needs to push the boundaries of what is possible. Our ongoing expansion of the motion plastics product world, coupled with the integration of digitalization and AI, is a testament to our long-term corporate strategy. We are making significant progress in embedding digitalization as a key technology at Igus, which will play a crucial role in our future growth and success.”

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German component supplier Schaeffler is leading the ReDriveS research project, an initiative funded by the German Federal Ministry for Economic Affairs and Climate Action. The project, which includes 25 partners from industry and academia, aims to develop an automated and scalable recycling concept for electric axle drive systems.

The project has a volume of over EUR 25 million, with funding exceeding EUR 16 million over a 36-month period. The technical focus is on robot-guided disassembly to recover materials such as rare earths, copper, aluminium and steel. This approach is intended to support the repair of drives, the reuse of subcomponents, or the recycling of materials to meet statutory requirements and secure supply chains.

A central component of the project is the development of a digital twin that processes data throughout the lifecycle of an axle drive. This digital model assesses the condition and geometry of units to determine whether they should be dismantled into main components – such as the motor, inverter, or transmission – or broken down further for material recycling.

The system is designed to be manufacturer-independent, allowing the technology to be used as an industry solution for original equipment manufacturers (OEMs) and recyclers. The project also explores data-based business models for axle drives enabled by this digital ecosystem.

Prof. Dr. Tim Hosenfeldt, Head of Central Technologies at Schaeffler, said, “With ReDriveS, we are launching a key project for the circular economy in electric mobility as consortium leader, together with the German Federal Ministry for Economic Affairs and Energy and strong partners. Our goal is to make electric axle drives significantly more resource-efficient through digital twins, automated disassembly and high-quality recycling – thereby securing raw materials and supply chains, reducing CO2 emissions, and strengthening Germany as a location overall.”

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BYD has updated its warranty terms for the Blade Battery in Europe, increasing the mileage limit to 250,000km while maintaining the 8-year duration. The extension applies to both battery electric vehicles (BEVs) and Super Hybrids and includes a guaranteed State of Health (SOH) of at least 70 percent. This change is retroactive, covering existing owners alongside new customers.

The Blade Battery utilises lithium iron phosphate (LFP) chemistry, which avoids the use of nickel and cobalt. Its design allows cells to act as structural elements, increasing the vehicle's torsional rigidity. This configuration reduces the volume occupied by the battery by 50 percent compared to traditional designs, intended to optimise interior space.

The battery has undergone testing, including nail penetration, where surface temperatures remained below 60deg Celsius. It has also been subjected to overcharge tests, oven tests at 300deg Celsius, and crush evaluations. According to BYD, the battery can exceed 3,000 charge and discharge cycles, indicating a service life of approximately 1.2 million kilometres.

Current models utilising this technology include the BYD SEAL, which reports a range of 570km on the combined cycle and the BYD SEALION 7, capable of DC charging from 30 percent to 80 percent in 18 minutes at a power of 230 kW.

Under the new terms, the specific battery cover sits alongside the standard vehicle warranty of six years or 150,000km. The electric drive unit remains covered for eight years or 150,000km, while the anti-perforation warranty continues at 12 years with unlimited mileage. The extension is designed to address user confidence regarding the longevity of energy storage systems in the European market.

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Suzuki R&D Center India (SRDI), a subsidiary of Suzuki Motor Corporation, has launched the Suzuki e-Micromobility Innovation Lab for Ecosystem (SMILE). Located within the International Automobile Center of Excellence (iACE) in Gandhinagar, Gujarat, the facility functions as a platform to develop Versatile micro e-Mobility (VmeM) solutions.

The laboratory connects technology from Japan with ideas from Indian startups and component manufacturers. The objective is to design mobility systems from a customer perspective and strengthen co-creation within the Indian ecosystem. The VmeM platform, previously announced in Japan as MITRA, was showcased during the Vibrant Gujarat event in Rajkot on 11-12 January before the opening ceremony on 13 January.

SMILE operates within iACE, an institution founded in 2015 by the Government of Gujarat and Maruti Suzuki India. The centre focuses on training and skill development, having provided education to over 10,000 individuals in automotive engineering and mobility systems. The establishment of SMILE follows a memorandum of understanding signed between iACE and SRDI in December 2024.

The lab intends to integrate vehicle manufacturing with technology from the startup sector to address infrastructure needs. Target applications include warehousing, air cargo, manufacturing plants, agriculture, and municipal services.

Katsuhiro Kato, Director and Executive Vice-President, Suzuki Motor Corporation, said, “We are pleased to see the VmeM, designed and developed by Suzuki, introduced in India through Suzuki R&D Center India. The VmeM platform represents Suzuki’s commitment to evolving future mobility. With the launch of SMILE at iACE, we will work closely with Indian industry, startups and government stakeholders to drive co-creation on valuable mobility solutions that support growth and sustainability. We also aim to serve the role as a key base for the global deployment of the VmeM platform by promoting continuous technological development.”

The initiative positions Gujarat as a base for the global deployment of the VmeM platform through ongoing technological development and stakeholder collaboration.

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Steelbird Hi-Tech India, one of the largest helmet and two-wheeler accessories brands, has launched Base X, a smart riding technology integrated into the Steelbird Fighter helmet range. The system is designed to provide connectivity and control for riders while maintaining a focus on safety standards.

The Base X system features a magnetic lock that serves as a power control, activating the device when the buckle is secured and switching it off when removed. The technology includes hands-free music control for track navigation and volume adjustment. It also integrates with voice assistants, allowing users to activate Google Assistant or Siri via a button on the helmet.

The technology offers three riding modes – Glide, Beast and Relax – which can be toggled using a dedicated button. For visibility, the system includes customisable rear indicator lights. The unit is powered via a Type-C charging port and provides up to 48 hours of playback.

The Fighter helmet housing this technology uses a high-impact shell design and a ventilation system. The product is priced at INR 5,999, aiming to make smart features accessible within the Indian market.

Rajeev Kapur, Managing Director, Steelbird Hi-Tech India, said, “Riding today is not just about reaching a destination — it’s about the experience along the way. With Base X, Steelbird is introducing a new era of smart riding technology that allows riders to control essential functions effortlessly while staying focused on the road. This innovation reflects our vision of blending safety, comfort, and technology into every ride.”

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