Sona BLW Precision Forgings Ltd. (Sona Comstar) has achieved two remarkable production milestones of 400 million differential gears and six million differential assemblies. 

Designing and manufacturing differential assemblies, precision-forged differential gears and other driveline parts, Sona Comstar makes auto parts that cater to Battery Electric Vehicles (BEV), Passenger Vehicles, Commercial Vehicles and Off-highway Vehicles. It is one of the largest manufacturers of differential assemblies for BEVs worldwide. 

With a focus on innovation and commitment to quality and customer satisfaction has enabled it to emerge as a preferred partner for leading automotive manufacturers worldwide, Sona Comstar is claimed to have a market share in India for differential gears of between 60 and 90 percent. The global share is said to be an estimated 8.1 percent in 2023. 

Catering to world's largest vehicle manufacturers, including seven of the top 10 passenger vehicle OEMs, three of the top 10 commercial vehicle OEMs, seven of the top 10 tractor OEMs and four of the top 10 electric vehicle OEMs, the company is committed to offering cutting-edge products to its customers to enable faster adoption of greener, safer, and smarter mobility in India and globally.

"With great pride, we celebrate these remarkable milestones in our journey," said V. Vikram Verma, CEO of Sona Comstar's Driveline business. "These milestones demonstrate our dedication to technology, innovation, quality, and customer satisfaction. I congratulate my team for their hard work and thank our customers for their continued trust in our products. As a company, we prioritise engineering excellence and innovation to develop new solutions for our customers. We are well-positioned to meet the global automotive industry’s evolving needs as mobility becomes greener, safer and smarter," he elaborated. 

Sona Comstar started producing precision forged differential gears at its plant in Gurgaon, Haryana, in 1999 and commenced production at another plant in Pune, Maharashtra, in 2005. The company marked the production of 100 million gears in 2013 and 200 million gears in early 2018 and achieved the 300 million milestone in October 2021. The next milestone of producing 400 million gear was achieved within two and half years, reflecting the company's strong growth.

Subsequently, Sona Comstar started manufacturing differential assemblies at its plant in Gurgaon in 2008. Later, in 2014, it expanded production to its Pune plant. In 2019, the company began production at a new, state-of-the-art plant in Manesar. In 2017, the company produced its one-millionth differential assembly. By 2023, it reached the milestone of producing five million differential assemblies. The company produced the next one million differential assemblies in less than nine months.

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Sterling Tools has entered into a partnership with MINIEYE, a Hong Kong-listed developer of intelligent driving and in-cabin solutions. The collaboration focuses on the deployment of Advanced Driver Assistance Systems (ADAS) and Driver Monitoring Systems (DMS) tailored specifically for the Indian automotive market.

As per the agreement, Sterling Tools will lead application engineering and on-ground adaptation. This involves tuning perception algorithms to account for Indian road scenarios, traffic patterns, and environmental conditions. The project aims to ensure that safety technologies, such as Autonomous Emergency Braking (AEB) and Lane Departure Warning Systems (LDWS), function reliably in local settings rather than relying on global configurations.

The partnership is positioned to meet upcoming Indian safety mandates. Effective 1 January 2027, regulations will require the fitment of ADAS and Driver Drowsiness and Attention Warning Systems (DDAWS) in new vehicle models. The scope of the collaboration covers both commercial and passenger vehicles, including technologies for Forward Collision Warning (FCW) and Blind Spot Monitoring.

MINIEYE provides technology that complies with EU General Safety Regulations and holds Automotive SPICE V4.0 CL3 certification. Sterling Tools is supporting this transition as part of a broader expansion into electronics and safety-critical components, which includes electric vehicle power electronics and motor solutions.

Anish Agarwal, Director, Sterling Tools, said, “Road safety and regulatory compliance are becoming increasingly important across both commercial and passenger vehicle segments in India. This collaboration allows us to work with a global technology partner to address the growing need for driver assistance and monitoring systems that are engineered for Indian operating conditions. At Sterling Tools, our focus remains on supporting OEMs with engineered, safety critical technologies aligned with upcoming regulatory requirements.”

Dr Liu Guoqing, Founder and Chairman, MINIEYE, added, “Partnering with Sterling Tools marks a vital step in bringing intelligent driving to India, leveraging Sterling Tools local expertise to translate technology into production-ready applications that enhance vehicle safety.”

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Faraday Future Intelligent Electric Inc. has released technical details regarding the Front AI Communication Ecosystem (F.A.C.E.), a system featured on the electric version of its FX Super One MPV.

The technology replaces the traditional front grille with a display and an AI avatar designed to act as a co-pilot and communication interface.

The system utilises multimodal interaction, including voice, gesture and touch, to respond to user needs. It is controlled via a smartphone application, allowing for the display of custom graphics, logos and streaming video while the vehicle is stationary. The hardware incorporates sensors that enable the AI agent to perceive its surroundings and interact with individuals outside the vehicle.

The F.A.C.E. system uses a Large Language Model (LLM) reasoning layer to interpret user intent and execute actions. Its functionality includes role-awareness personalisation, which distinguishes between owners, family members and unknown persons to provide appropriate responses.

The system supports proactive communication, such as initiating responses when someone approaches the vehicle to improve safety. Users can also interact with the vehicle’s voice assistant from the exterior to check status or request access. The FX Super One platform is engineered to support both battery electric and AI hybrid extended range (AIHER) powertrains.

The FX Super One is positioned as a mass-market MPV for the United States. Faraday Future has established a three-stage delivery structure for the model:

• Phase One: Deliveries to FX Partners are expected to begin in the second quarter of this year.
• Phase Two: B2B partner deliveries and production ramp-up are scheduled for the third quarter.
• Phase Three: Full-scale consumer market deliveries are targeted for the final quarter of this year or the first quarter of 2027.

Max Ma, Global CEO, FX, said, “Offering technology like our unique F.A.C.E system in a new category of vehicle will be a game changer in the marketplace. It will allow users to connect with the world in a totally new way. It can express itself and communicate to the world in a way never seen before in a vehicle. The FX Super One is not just a new MPV, it is the first mass-market, first-class Embodied AI MPV designed for the U.S. market, where intelligent space, AI interaction, sensing, computing and power and extended-range capability come together in a single platform.”

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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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