… by Dr Balaji Venkataraman, President, TVS Sensing Solutions
The trend of the Indian automotive industry is moving towards the future of EV technology. This is resulting in an increased need for intelligent, precision engineered automotive components (i.e., sensors, power modules, actuators, and control electronics). Over time, the automotive component industry has significantly impacted the growth of India by taking advantage of global business opportunities and improving India’s position within the global value chain. In addition to having more complex architectures, EVs require a higher standard for safety and efficiency, so there has been an increase in the amount of money that is invested in developing advanced automotive components that allow sustainable mobility and intelligent vehicle systems. The Indian market is quickly growing in size and potential due to the rapid increase in automation around the world. As more companies are increasing their demand for talent and innovations across countries; many automakers have begun to develop more extensive research centres throughout various parts of India in order to tap into the growing pool of engineering talent available in India for their domestic and export markets. An additional aspect of this evolution of the Indian automotive engineering industry is the increased opportunity for Indian automotive companies to develop the required components, such as sensors and electronic systems and to continue to expand their capabilities in the design and development of new technology for these components. These changes have driven manufacturers to develop hybrid manufacturing practices that provide improved accuracy, scalability, and performance.
Manufacturing High-Precision EV Auto Components
Auto components such as sensors, DC-DC converters, Tire Pressure Monitoring Systems (TPMS) and Acoustic Vehicle Alerting Systems (AVAS) are seeing strong innovation in the EV category, particularly in high-precision components With India’s growing engineering depth, component manufacturers are increasingly positioned to develop solutions that enhance power efficiency, functional safety and overall vehicle intelligence. EVs and hybrid vehicles demand consistent investment across areas such as energy storage optimisation, efficient power conversion, integrated sensor networks and charging-system electronics. As a result, manufacturers are prioritising the development of advanced components that combine smart features, connectivity and improved reliability to meet evolving EV platforms. Collaborative programmes between OEMs, Tier-1 suppliers and technology players continue to accelerate progress, enabling faster prototyping, better system integration and stronger competitiveness in global markets.
Even with the temporary slowdown during the pandemic, the EV component segment has continued its upward trajectory, supported by steady consumer adoption and a clear industry shift toward electrification.The industry has shifted to being more focused on the development of new parts, as well as developing partnerships with other businesses and developing their own products locally. Initiatives such as the PLI and FAME programmes, as well as tax breaks for research activities, have also strengthened the infrastructure needed to produce high precision EV components. Many of the Indian states have now created EV supportive policies, and with that comes many opportunities for skilled workers in the areas of electronics, manufacturing and automotive engineering. Collectively, these changes indicate that the industry is now ready to scale up production of advanced EV components such as sensors, power electronics, TPMS and AVAS, all of which will pave the way to creating safer, more efficient and environmentally sustainable mobile systems.
Hybrid Manufacturing Technologies for Complex EV Components
Many hybrid manufacturing technologies have recently been added to help EPV´S build more complex parts. All types of hybrid methods (Combination of additive/subtractive) and all forms of precision assembly techniques, are being used by users of these methods in order to meet their growing performance expectations. In producing EV´s components, (Sensor, Modules, Housings, etc) these manufacturers are able to produce all types of parts with improved structural durability, thermal performance, precise tolerancing and scalability. Critical aspects such as EMI/EMC compliance for sensors, thermal management of power electronics, sealing of electronic assemblies, and structural integrity of housings are addressed through advanced hybrid processes. The integration of digital-twin-based manufacturability optimization further enhances design accuracy, reduces production errors, and ensures that each component meets stringent quality and reliability standards
System Integration, Reliability Engineering and Quality Validation for EV Components
As EV technologies become increasingly interrelated, the requirement for integrating these technologies requires a very high level of customization, consistent quality, long-term dependability and timely availability of all vehicle components. In order for manufacturers to satisfy this demand, they are utilizing enhanced reliability engineering to assist them in their processes and aligning their manufacturing processes with the needs of both their customers and regulatory authorities. Additionally, they’re focusing on continuous improvement, cost-effectiveness and strong post-sales support. The quality validation process for EVs has become very important for the EV industry and is realized through a formalized planning process, an established workflow and accurate execution using Total Quality Management (TQM). Therefore, the EV industry is investing in emerging technologies related to EVs, training its employees to maintain a high level of up-to-date skills and forming collaborative partnerships to keep pace with advances in mobility.
The Road Ahead
India’s EV industry has already developed and will continue to be driven by intelligent, high-quality manufacturing ecosystems comprised of intelligent components and advanced engineering capabilities including automated assembly processes); these factors will drive the development of India’s next generation of mobility solutions. Increased demand for the development of new technologies such as precision built sensors, ECUs, TPMS, AVAS, etc. will increase the requirements on manufacturers to develop their own expertise in areas such as materials science, electronics, and software-controlled automation. Hybridization of major manufacturing processes will provide the basis for the ability of manufacturers to develop the required level of performance and reliability based on the needs for next-generation EVs while ensuring scalability and cost-effectiveness system integration, reliability engineering, and rigorous qualification will enable manufacturers to develop components that work together effectively and efficiently in EV systems, which are becoming increasingly complex. The establishment of supportive government policies, the availability of skilled engineers and the increase in investment in R&D will provide a solid foundation for sustainable mobility in India and allow for the delivery of high-performance EVs with increased safety, efficiency and performance and ultimately moving towards cleaner, smarter and more resilient vehicles.
