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)

Delhi NCR-headquartered electric vehicle company Omega Seiki Mobility (OSM) has partnered Electra AI to integrate battery health monitoring across its fleet operations.

The collaboration incorporates Electra AI’s analytics platform into OSM’s electric commercial vehicles. The technology enables real-time tracking, predictive maintenance and state-of-health diagnostics for battery packs. The data metrics aim to support warranty management, optimise vehicle uptime, assist financing assessments and provide residual value tracking for secondary market sales.

Uday Narang, Founder and Chairman, Omega Seiki Mobility, said, "The next phase of EV growth in India will not be driven solely by new vehicle sales, but by the creation of a credible and thriving secondary market. Battery health is the single biggest determinant of an EV's residual value, and until that can be measured transparently, the used EV market will remain constrained. Through our partnership with Electra AI, we are bringing unprecedented visibility into battery performance, enabling buyers, financiers, and fleet operators to make informed decisions with confidence. This will help improve resale values, unlock greater access to financing, and accelerate the adoption of electric mobility by ensuring that EVs remain valuable assets throughout their lifecycle."

Vivek Dhawan, Chief Strategy Officer, Omega Seiki Mobility, said, “As electric mobility scales, the industry must move beyond selling vehicles and focus on delivering intelligence that improves asset performance throughout its life. By integrating Electra AI's advanced analytics into our ecosystem, we will gain deeper operational insights that help enhance fleet productivity, reduce unplanned downtime, strengthen warranty management, and support data-driven product development. This collaboration represents an important step towards building a smarter, more efficient, and technology-led mobility ecosystem that creates tangible value for customers, partners, and stakeholders alike."

Fabrizio Martini, Co-Founder and Chief Executive Officer, Electra AI, stated: “Vehicle makers like OSM are being asked to put more capable, more affordable EVs on the road every year — and to stand behind them with confidence. Our AI Brain for Batteries platform gives them the real-world intelligence to do exactly that: design better vehicles, offer stronger assurance to their customers, and keep fleets running. That’s what battery intelligence is for — turning data into trust across the whole ecosystem, from the OEM to the financier to the operator.”

The deployment aims to support commercial fleet operators across India by reducing maintenance delays and improving total cost of ownership visibility.

Hyundai Motor India, in partnership with Radio Mirchi, has launched the Hyundai Traffic Quality Index, a standardised traffic rating framework designed to convey real-time road conditions across seven major Indian cities. The initiative operates across Delhi, Mumbai, Bengaluru, Chennai, Hyderabad, Pune and Kolkata.

The system translates live traffic inputs, on-ground reports and official traffic police advisories into a numerical scale from 1 to 10. The ratings are categorised into three colour-coded tiers: 1 to 3 represented in green for light traffic, 4 to 7 in yellow for moderate traffic and 8 to 10 in red for heavy congestion. Updates are broadcast over Radio Mirchi’s audio network to inform drivers during commutes without requiring direct interaction with mobile devices.

The system processes real-time location data alongside updates regarding road closures, diversions, and civic works. Hyundai Motor India and Radio Mirchi plan to expand the index to additional urban centres in subsequent phases of the project.

Virat Khullar, Head of Marketing, Hyundai Motor India, said, “At Hyundai, our commitment to road safety has always extended beyond the vehicle itself. For over three decades in India, we have continuously invested in technologies and initiatives that make mobility safer and smarter. With the Hyundai Traffic Quality Index, we are taking that commitment a step further by empowering commuters with actionable information. We believe informed and technology enabled decisions lead to safer roads, calmer driving behaviour and better commuting experience. Our vision is for Hyundai Traffic Quality Index to evolve into a daily utility that millions of Indians rely on, much like they check the weather or the Air Quality Index before stepping out.”

Yatish Mehrishi, Chief Executive Officer, ENIL, said, “Radio has always been a trusted companion for people on the move. With the Traffic Quality Index, we are taking that relationship a step further by making traffic information simpler, more consistent and more useful for everyday commuters. Our presence across cities, supported by our RJs, on-ground teams and real-time local insights, gives us a unique understanding of how people experience their daily commute. TQI brings these insights together in an easy-to-understand format that can help people make better decisions on the road. We are delighted to partner with Hyundai to build a public utility that can make urban commuting smarter and safer. It is a strong example of how media, technology and local intelligence can come together to solve an everyday consumer need.”

ACP Ravindra Pandit of Delhi Traffic Police, added, “The Hyundai Traffic Quality Index is a commendable initiative that empowers us to keep commuters informed about congestion, diversions, and other traffic-related issues on specific routes. By receiving timely and accurate updates, motorists can make informed decisions and opt for alternate routes, reducing inconvenience and easing congestion. Timely dissemination of reliable traffic information benefits both the public and traffic authorities, making overall traffic management more efficient and commuter-friendly.”

Anil Patil, Regional Transport Officer for Mumbai West, commented, “Understanding and managing traffic more effectively has become increasingly important today. TQI will help us better understand traffic conditions, improve awareness among citizens, and provide valuable support in making traffic management more efficient.”

IPS Manoj Patil, Additional Commissioner of Police for Pune City, said, “Traffic Quality Index can give the traffic police a different kind of study and analysis. Especially because it will include inputs and suggestions coming directly from citizens. So, we will get an independent understanding of the actual traffic situation. I feel this can be extremely useful for us while planning future traffic management as well as infrastructure projects. So, I really welcome this initiative If we are able to measure the traffic quality index in this manner, it will definitely have an overall impact on our deployment and the way we manage traffic.”

Dr B. Shamoondeswari, Additional Commissioner of Police (Traffic) for Greater Chennai Police, said: “Just like AQI helps us understand air quality, TQI will help us understand traffic quality. It’s a great initiative that can make people more aware, help manage congestion, and contribute towards smoother traffic movement in our cities.”

ACP A. Krishnaiah of LB Nagar Traffic Police in Hyderabad noted: “The Hyundai Traffic Quality Index is a valuable initiative that helps commuters stay updated on traffic congestion, diversions, and other route-related issues. Access to timely and reliable traffic information enables motorists to plan their journeys better and choose alternative routes when required. This not only reduces travel inconvenience but also helps ease traffic congestion. Overall, the initiative supports both commuters and traffic authorities by making traffic management more effective, responsive, and commuter-friendly.”

Open-source autonomous driving software company TIER IV has joined the Next-Generation Edge AI Semiconductor Research and Development Programme, led by the Japan Science and Technology Agency (JST). The initiative focuses on the development of a software-defined system-on-chip (SoC) designed for Level 4 autonomous driving applications.

As part of the programme, a team led by Professor Yoshihiro Kawahara at the University of Tokyo is researching physical AI chip design based on specific use cases. Concurrently, TIER IV is developing the logic design for an AI chip aimed at processing inference for end-to-end autonomous driving systems. TIER IV plans to open-source the resulting logic design, compiler, and software toolchain to allow semiconductor manufacturers and developers to modify and build upon the hardware architecture.

The project focuses on developing hardware architectures tailored for Transformer AI models, which process sensor data from cameras and point clouds for perception and motion planning.

The chip design incorporates dedicated circuits for matrix multiplication and attention mechanisms, aiming to reduce power consumption from external memory transfers. To maintain software adaptability, TIER IV is integrating the Tensor Operator Set Architecture (TOSA) as an intermediate representation layer between AI frameworks such as PyTorch and the chip hardware.

The initiative also applies formal verification techniques to mathematically trace numerical consistency during AI model compilation.

Shinpei Kato, Founder and Chief Executive Officer, TIER IV, said, “Advances in AI have been accelerated by powerful computing platforms, including GPUs, which have enabled rapid progress across the industry. As Level 4 autonomous driving moves toward broader deployment, we believe the next step is to complement these platforms with computing architectures designed for real-world and real-time requirements. Through this initiative, we are introducing a software-defined and open approach to AI chip design that combines power efficiency, adaptability, transparency and verifiability. In particular, the ability to understand how an AI model is transformed for execution and to verify the correctness of that processing will be increasingly important as autonomous driving systems are deployed in safety-critical environments. By extending the open-source philosophy behind Autoware from software to AI chip design and related toolchains, we aim to create an open ecosystem in which automakers, semiconductor manufacturers and developers can build upon the technology and continue advancing their own systems. This represents an important step toward a scalable, adaptable and reliable computing foundation for Level 4 autonomous driving.”

Professor Yoshihiro Kawahara stated, “In physical AI applications such as robotics and autonomous driving, GPU power consumption has long been a major bottleneck for deployment on battery-powered devices. This project aims to fundamentally overcome this constraint through a functionally differentiated chip design backward-mapped from specific use cases. I look forward to TIER IV developing chips responsible for high-level decision-making – specifically, the high-level behavioural layer that handles the thinking process essential for end-to-end physical AI and autonomous driving. As the leading force behind Autoware, the global standard open-source software for autonomous driving, TIER IV is democratising design, with an approach spanning application requirements to hardware. This enables applied researchers to shape their ideal semiconductors. This initiative, supported by an open ecosystem, has the potential to lay the foundations for a steady stream of Japanese startups creating high-value semiconductors.”

American automotive supplier Stoneridge, Inc. has announced details of its EVO ECU Platform, which will debut at IAA Transportation 2026 in Hanover, Germany.

The electronic control unit (ECU) is engineered for commercial vehicles, buses, coaches and off-highway applications to consolidate system architecture and support software-defined capabilities.

The platform replaces multiple individual control units with a centralised processing architecture designed to manage vehicle data, enable remote software updates and facilitate diagnostics.

The ECU is developed in collaboration with technology partner Renesas Electronics using its R-Car system-on-chip technology and the hardware is built to withstand operating conditions involving temperature variations, vibration and dust exposure.

Christian Leblanc, Global Vice-President of Product and Project Management, Stoneridge, said, “Commercial vehicles are becoming increasingly connected and intelligent, but traditional vehicle architectures were not designed to support the pace of innovation happening today. EVO provides a scalable platform that helps simplify integration, improve vehicle performance and give our customers the flexibility they need to adapt as technology continues to evolve.”

“Fleet customers were at the centre of our development process. EVO helps enable faster troubleshooting, fewer service interruptions and the ability to continuously improve vehicle capabilities throughout the vehicle lifecycle,” added Leblanc.

The software structure was developed alongside Green Hills Software to segregate safety-critical operations while allowing system updates. Additionally, Stoneridge partnered with indie Semiconductor to produce the platform's image processor, supporting camera integration and driver assistance systems.

Natalia Noblet, President and CEO, Stoneridge, said, “Our industry is undergoing a significant transformation, driven by increasing connectivity, automation and evolving regulatory requirements. EVO represents our commitment to helping customers navigate that transformation with a flexible platform designed to support innovation today and tomorrow.”

Aish Dubey, Vice-President and Head of the HPC SoC Division, Renesas Electronics, commented, “Stoneridge’s EVO ECU Platform demonstrates how commercial-vehicle manufacturers can modernise vehicle electronics for demanding operating environments. Our collaboration brings together Stoneridge’s commercial-vehicle expertise and Renesas’ R-Car system-on-chip, power-management and programmable mixed-signal technologies to create a scalable, automotive-grade foundation for connected and software-defined commercial vehicles.”

The system has undergone field testing within the Stoneridge Innovation Truck demonstrator vehicle, which will be exhibited alongside the platform at the Hanover trade show.