Stratasys, a global leader in additive manufacturing or 3D printing technology, helps Indian aerospace, automotive, healthcare and consumer products industries design and make prototypes, manufacturing tools, and production parts faster and cost effectively.

Several OEMs and Tier-1 companies in these industry segments are its customers who want high value products at very reasonable prices. In an interaction with T Murrali of this publication, Rajiv Bajaj, Managing Director, Stratasys India and South East Asia, said, “We are changing the game by giving industrial production-grade machines at affordable prices. We have a lot of takers for them across industries in the Tier-2& 3 cities also.” Edited excerpts:

Q: In India, is additive manufacturing still confined to R&D for making prototypes? What is the next step in the automotive sector?

Bajaj: The car companies we have in India are globally competitive, keeping pace with what is happening around the world. The differentiation we see as a technology provider is the level of technology adoption by the local OEMs. Similar-sized OEMs elsewhere in the world will have a series of our machines whereas in India they are just 1 or 2 each, most of them with the auto OEMs. It also has to do with the technology adoption rate and the trend of product development and differentiation which came in rather late.

 Secondly, prototyping is a well documented area; people use it day in and day out. Companies like Honda, that do only manufacturing in India, are adopting it for their jigs and fixtures. The third stage we look at is personalisation where one can use the 3D printed part in a portion of the vehicle, which has been done with BMW MINI, and Daihatsu in Japan. We don’t have any use case in India as yet. We are looking at possibilities here.

Q: Are there some applications where it can be used?

Bajaj: Now we are talking about not just back-end or R&D use but actual customer experience. There we are giving tooled-up parts with multiple finishes. There are finite possibilities with the new numbers and quality of parts being manufactured. 3D is also used as a marketing tool. Typically, people look at it as a device to save money or time as this is a revenue generation tool.

Q: So even if you make 10,000 parts, each one can be customised?  

Bajaj: Yes, absolutely; it’s mass customisation.

Q: Do you see opportunity globally and in India to replace traditional manufacturing by 3D, and to what extent?

Bajaj: There is no simple yes or no answer to this. It involves a deep understanding of how the two processes work. If volumes are a few thousands, yes; but if it is in lakhs, then maybe not. The most intelligent organisations would be the ones who would use a mix-and-match of this technology. Additive doesn’t mean it should remove subtractive. Intelligence lies in knowing when to use additive and where to leverage subtractive, and vice-versa. Combining these two will make for a very efficient organisation.

Q: Will this find a key role in low volume parts? 

Bajaj: Yes, as well as complicated parts and in the aftermarket for different models. Even enthusiasts like Jay Leno will find a use for this. In fact Leno has bought a 3D printer from Stratasys to make parts for his collection of vintage cars. It’s a useful tool for motor enthusiasts to make parts that are not available in the market.

Q: Do you see additive manufacturing for lightweighting?

Bajaj: Parts consolidation is a very direct outcome of 3D printing because, for example, it can print a chain with interlock whereas in the traditional process each part would be a separate entity. In an aerospace part we consolidated some 100 plus parts into one unit. In automotive, now many areas for this are emerging for limited production; mass production would take some more time but it will come. When we talk of lightweighting, making prototypes earlier was quite difficult but today with this technology we can make very complex prototypes and validate the design. Once it is validated it can use any method: for low volume additive, for high volume something else. That’s the advantage. Also, in assembly, we can check minute gaps in the line very accurately. Changes in tooling can be done immediately instead of waiting for a long period as customisation has to be done in the shortest period possible.

Q: Would this help reduce the number of iterations?

Bajaj: Actually I can do more iteration by trying out newer ideas. This will help enhance the quality level at the design stage itself. We have to find a balance between the additive and the subtractive.

Q:  Would the customer complaints reduce when you make a product faster?

Bajaj: Obviously, as I am designing quality into the process and product from day one; it helps me take informed decisions. Basically, what the customer wants is a good, tangible product.

Q: What is the response you get from customers who have not taken up this technology as yet?

Bajaj: In today’s scenario there would be very few customers in the automotive supply chain who have not experimented with 3D printing. If they are not using it directly they are getting services done outside. The expectations from customers is different; some want better quality, some want it faster, some cheaper and so on. Most of them are experimenting so that this should become a part of their process.

Q: Are there other concerns than cost?

Bajaj: In India, cost is a big concern; customers want high value at the most reasonable price; they are not looking just for low cost. So there is pressure; that’s why a lot of innovation helps. A company cannot just copy paste; it has to innovate. In 2015 our lowest cost of the printer in FDM series was around INR 60 lakh. Today, we have given the same technology on a different platform for INR 15 lakh. That’s how we are changing the game, giving the same class of industrial production grade machines at an affordable price. This has found a lot of takers for us in the Tier-2&3 cities, not just automotive but across industries.

Q: There might be apprehension among your potential customers that if they buy a machine from you they would have to be wedded forever to your company to get the material. Is that true or will they be free to choose their own material from the market for use?

Bajaj: For most of our technologies it is true but we are working on a new technology called SLA which is our only platform where the consumer can buy material elsewhere. The problems with 3D printing are many. Let us say if you make your material open and then the customer comes and says the parts are not printing correctly; then where do you fix the blame? That becomes a big problem. The reason why we keep it to us is not because we want to charge customers more, but because we want to give them 100 percent accurate results all the time. Predictability and repeatability are problems that 3D printers at entry level are facing every day. By controlling the oven temperature and the material properties we are able to achieve 100 percent accuracy. When companies like Maruti tell us there are some challenges, we work with them to sort it out.

It is like when the customer buys a car and goes to the spurious market to get parts. When the vehicle fails they come and complain to us. We check the car and tell them the company is not responsible for whatever parts the customer fits in. Even insurance companies do not entertain such claims. If you want consistent quality and most desirable product performance you will have to stick to some standards.

Q: Do you see Stratasys to become even a supplier to vehicle manufacturers or Tier-1s?

Bajaj: It is not done in India as yet but globally we do run Service Bureaus. The BMW MINI project is all done by our Bureaus.

Q: Is this like software as a service where they can use your facility?

Bajaj: Yes, they have to just give us the software data and we will be able to print it. But that is not the real intelligence of the service bureau. The services we provide are very high-end; redesigning the entire thing, adding more colour variants, giving a new look to the car. These are the kind of services we provide where 3D printing is a part of the process. We take into account all the special requirements the customer wants. We have done complex projects in India and our overseas offices as a service.

Q: Which are the markets that are very attractive, where you have more inroads as of now? Going forward, how will it be?

Bajaj: Automotive is our sweet spot, globally (around 25 percent) and in India (30 percent). I see it as a major place for expansion because compared to global standards the technology adoption with these companies is very low. I believe if they have to compete in testing times like this there is no other way than to come out with products faster and cheaper. Technologies like Stratasys 3D printing are tailor-made for this. Despite the slowdown we are very bullish about the automotive market because of the lack of penetration in it. It’s a technology life cycle, similar to the software industry where the cycle came from the US and went on to Europe and to Asia before coming to India.

Q: How do you compare with aviation as you are the only one certified by the aviation industry?

Bajaj: For aviation, we are limited to plastics at this point in time so the parts made by us are more suitable for the cabin interior. India is more about defence aviation where the aircraft interior is not that critical. While HAL, DRDL, etc are all using our technology, mass proliferation would occur when companies like Boeing and Airbus have their complete setup in India. We need civil aircraft to be manufactured in India to see that kind of growth; there are none at present.

Q: For automotive, what are the key drivers of growth globally and in India?

Bajaj: One is the quest for innovation through rapid prototyping. Two, the product development cycle time has reduced by 50 percent in the last four years. If a new platform time was 3 years earlier, today it is under 18 months. In the past two years, any automotive company that has not come up with newer models at a faster pace has not survived. To keep the momentum going in the market they have to come up with new products. If they have the right product at the right price in India their business will certainly grow. (MT)

 

BOX 

User Forum

The 3rd edition of Stratasys India User Forum in Bengaluru recently had participation from over 620 industry leaders and end-users. Organised by Stratasys, a global leader in 3D printing and Additive Manufacturing (AM), the Forum was a platform for professionals to exchange views on the latest 3D printing trends, applications, and the best practices across key sectors in India.

Michael Agam, President, South Asia, Stratasys, said the User Forum brought together several leading brands such as Maruti Suzuki, Ashok Leyland and Honda Cars in the Indian ecosystem, that have used Stratasys’ products to innovate. This reiterates why India is a key market for the company.

Saurabh Singh, Head of Design Studio at Maruti Suzuki India Ltd, highlighted how the brand has been able to leverage 3D printing to provide high quality, ergonomically suited and distinctly personalized offerings, thereby enhancing the overall customer experience.

Sundaresan, Vice-President, Electric Vehicles and eMobility Solutions, Ashok Leyland, said that AM helped the company save about 14,138 days of hour-utilization and nearly INR 74 lakh in manufacturing costs. He said Ashok Leyland made clutch housing using AM to carry out fitment checks and it helped to contain the time to three days against close to 60 days in the conventional method. AM helped also to keep the time schedules for the development of blower cover and meet the CMVR regulations. The company made prototypes and parts for the initial production lot. The whole exercise was completed in a couple of days as compared to 90 days in the conventional method. Similarly, the three-axis intake pipe was made in a day as opposed to the usual three months. It also made a scaled concept of the seven-speed gearbox having geometric complexity. For electric vehicles the company made traction motor stator sector in AM, which helped in physically measuring the slot-fill, evaluate ease of winding and measure external portions of end-winding. “For smaller volumes also AM is economical. For advanced mobility it plays a key role in the combustion chamber”, Sundaresan added.

Bhushan Chandna, Manager, Business Excellence, Honda Cars, explained how the brand has spearheaded the use of additive manufacturing in the auto sector, especially with the use of 3D-printed jigs and fixtures. (MT)

Lauritz Knudsen Electrical and Automation has entered into a partnership with Orion Racing India, the Formula Student team of K J Somaiya School of Engineering, Mumbai.

The collaboration is intended to support engineering students at the grassroots level and strengthen the development of electric mobility capabilities within India.

The partnership focuses on hands-on learning and experimentation in the design of electric and autonomous vehicle platforms. Lauritz Knudsen aims to foster skills in power distribution systems and electric vehicle charging infrastructure, areas central to the company’s industrial focus.

Orion Racing India has operated in student motorsport for nearly 20 years, transitioning from internal combustion engines to electric prototypes in 2019. The team uses electric race cars as a platform for students to address challenges in – energy management, power systems, vehicle safety and performance engineering.

Naresh Kumar, COO, Lauritz Knudsen Electrical and Automation, said, “India’s electric mobility journey will be shaped by the ecosystem we build today. At Lauritz Knudsen, we believe meaningful change begins early, when young engineers are encouraged to build, experiment, and apply their learning to challenges. By engaging with students who are actively working on electric vehicle technologies, we are helping develop future ready talent that will play a defining role in India’s mobility and energy future.”

Dr. Ukrande, Director of K J Somaiya School of Engineering, added, “Orion Racing India has a long and proud legacy of representing K J Somaiya School of Engineering at Formula Student competitions over the years. What makes this journey special is the continuity each batch of students builds on the learning, experience, and spirit of those before them. Through hands-on work on electric racecars, our students move beyond textbooks to real engineering challenges. Support from industry partners like Lauritz Knudsen further strengthens this learning ecosystem and motivates students to innovate in areas critical to India’s mobility future.”

Horse Powertrain has announced kAIros, a company-wide artificial intelligence (AI) initiative led by its Horse Technologies division. The programme aims to reduce time-to-market by nearly 50 percent, decrease low-value process work by 40 percent and improve design cycle efficiency by 25 percent.

The initiative is supported by Nvidia, Google Cloud and Deloitte, focussing on engineering, production and business operations.

At the core of the initiative is the Horse Powertrain AI Factory, which supports model training, simulations and digital twins. The infrastructure is designed to generate training data to refine models and improve real-world deployment.

The technical framework includes:

• Nvidia RTX PRO servers equipped with Blackwell Server Edition GPUs.
• Google Cloud NVIDIA RTX 6000 Blackwell Server Edition GPUs.
• Nvidia AI software, including CUDA-X, Omniverse and Cosmos, to accelerate application development.
• Google Gemini Enterprise for the deployment of AI agents to automate coordination tasks.

The kAIros initiative supports physical AI, connecting real-world operations with virtual systems in real time. This integration enables autonomous decision-making for cobots, automated guided vehicles and smart machinery. Key applications include video-based quality inspection, product simulation and robotics for process optimisation across factories and logistics.

A Centre of Excellence has been established to lead internal AI development. This multifunctional team will build applications to scale industrial expertise across the organisation and improve predictive accuracy in propulsion solutions.

NXP Semiconductors has announced a series of robotics solutions designed for real-time data processing, sensor fusion and motor control. Developed in collaboration with Nvidia, these ready-to-deploy systems implement the Nvidia Holoscan Sensor Bridge with NXP’s system-on-chip (SoC) technology to reduce component count, power consumption and costs in robotic development.

The solutions focus on Physical AI, which requires low-latency data transport to synchronise motion and sensor data. By integrating the Holoscan Sensor Bridge into NXP's software, developers can establish a direct transport route between a robot's body and its central processing unit.

The architecture incorporates several NXP technologies:

• i.MX 95 Applications Processor: A machine vision solution designed to deliver high-bandwidth data to the robot brain.
• i.MX RT1180 Crossover MCUs: A motor control solution based on a kinematic chain.
• S32J TSN Switch: Aggregates motor control data and provides direct connectivity to the brain using Time-Sensitive Networking (TSN) and EtherCAT protocols.
• Asymmetric Data Transport: Technology acquired through Aviva Links to manage high-throughput data across the robot body.

The unified architecture is designed to support humanoid form factors, which require complex motor synchronisation and real-time perception. NXP’s automotive-grade networking and functional safety expertise are used to ensure the reliability of these systems in physical environments.

Charles Dachs, Executive Vice-President and General Manager, Secure Connected Edge at NXP Semiconductors, said, “Physical AI is redefining what machines can do in the real world, and humanoid robots represent the most complex expression of that revolution. By combining NXP’s deep expertise in edge processing, secure networking, functional safety and real-time control with Nvidia robotics platforms, we are greatly simplifying physical AI development, enabling seamless connectivity between the physical AI edge and the central brain. This is just the beginning of what NXP will deliver to accelerate the ecosystem for physical AI.”

Deepu Talla, Vice-President of Robotics and Edge AI, Nvidia, commented, “The development of autonomous machines requires a high-performance computing architecture that can synchronize complex motor controls with real-time perception. By integrating Nvidia Holoscan Sensor Bridge into its edge portfolio, NXP is providing developers with a scalable foundation to accelerate the deployment of physical AI.”

Tokyo-headquartered deep-tech company TIER IV has announced that it has developed new software stacks for Level 4 autonomous driving powered by data-centric artificial intelligence. The software is available via Autoware, an open-source platform, and is designed to be hardware-agnostic, supporting various system-on-chip (SoC) and sensor configurations.

The software stacks are built on an end-to-end (E2E) architecture and offer two primary configurations to allow adaptability across diverse driving environments:

• Hybrid System: Utilises perception and planning AI. It employs diffusion models to capture temporal changes in surroundings and generates trajectories by combining machine learning models with environment perception.
• E2E System: Integrates perception, planning, and control into a single learning process. It uses world models to treat surroundings and driving status as vector representations, creating a pipeline from recognition to vehicle operation.

Automakers can use TIER IV’s machine learning operations (MLOps) platform to iterate AI models. The platform manages data-quality validation, anonymisation and tagging, while generating synthetic and real-world datasets for system evaluation.

TIER IV has commenced 60-minute test runs in three global hubs to validate the technology under distinct traffic conditions:

• Tokyo: Collaborating with the University of Tokyo using a Toyota JPN TAXI to evaluate urban hub-to-hub travel.
• Pittsburgh: Partnering with Carnegie Mellon University using a Hyundai IONIQ 5 for robotaxi tests between Pittsburgh International Airport and the university.
• Munich: Working with the Technical University of Munich using a Volkswagen T7 Multivan for safety evaluations in European urban scenarios.

While safety drivers remain on board to comply with local regulations, no manual intervention is expected during normal operation.

Shinpei Kato, Founder and CEO, TIER IV, said, “To achieve Level 4+ autonomy, we need technology that evolves autonomously alongside the environments it serves. Our new data-centric AI models and collaborative MLOps platform provide a common language and a shared foundation for the entire industry. By working with research institutions, industry leaders and the development community to advance autonomous driving technology through Autoware, we are creating an open, transparent environment that fosters continuous, collective innovation for the benefit of society.”

Yang Zhang, Chairman, Autoware Foundation’s Board of Directors, said, “Autoware serves as the global foundation where researchers, corporations and developers collaborate to advance autonomous driving software. Our collaboration with TIER IV strengthens the international framework for validating and refining E2E autonomous driving through real-world deployment. By testing across three continents, we are driving standards-based innovation and expanding an open ecosystem that lowers the barrier for a diverse range of partners to join and contribute.”

Yutaka Matsuo, Professor at the University of Tokyo, added, “The release of these software stacks and MLOps platform is a vital step toward deploying advanced AI models in industrial applications. By accumulating data from Japan’s distinctive traffic environments through our Tokyo testing and contributing those insights back to Autoware, we aim to further bridge the gap between academic research and real-world deployment.”