When speaking of sustainability, EVs are touted as the next game-changers in the global automobile industry. Because why not? They are the way forward for a safer and more sustainable environment!

So, what exactly are EVs?

An EV is an electric vehicle powered entirely or partially by electricity. They have minimal operating costs due to fewer moving parts to maintain. Plus, they are also environmentally beneficial due to their usage of little to no fossil fuels (LPG or diesel). While some EVs employ nickel metal or lead-acid hydride batteries, lithium-ion batteries are now the industry standard since they offer a longer lifespan and a low self-discharge rate of only 5% each month. These are the three types of EVs available: –

• Battery electric vehicles

• Hybrid electric vehicles.

• Plug-in hybrid electric vehicles

The Current Scenario of EV Manufacturing in India

Despite having the world’s largest untapped EV market, particularly in the two-wheeler category, India is a little behind the curve and its path to an electric vehicle future still has a few potholes. However, with numerous automakers rapidly introducing EVs, the usage of these vehicles has surged considerably in the past few years. According to a recent analysis, the market for electric vehicles will be valued at ₹475 billion by 2025. Electric two-wheelers are expected to attain a penetration of 15% by 2025, up from 1% at present.

 

The Indian Government’s Effort to Go Green 

Electric mobility is now a major priority for India as the country works toward its 2070 goal of being “zero-emission.” According to NITI Aayog, the Indian EV market will include 30% to 70% of cars, 40% of buses, and 80% of two and three- wheelers by 2030. At the COP26 Summit in Glasgow, the Indian government unveiled the one-stop EV info website to educate both Indian and global audiences on the various aspects and concerns of EV ownership and adoption. The Indian government has put a premium on clean mobility, as evidenced by recent changes to the FAME (Faster Adoption and Manufacturing of Hybrid and Electric Vehicles in India) II plan to make electric two-wheelers more accessible to the common man. Putting EV manufacturing in India as a top priority, about 1,65,000 electric vehicles worth US $75.16 million have been supported as of November 25, 2021, under phase II of the scheme.

Frontrunners Helming the Change

Many leading industry players, like Mahindra Electrics, OLA Electric Mobility Pvt., and Ather Energy, have branched out operations in recent years to tap into the Indian EV market’s potential. Tesla Inc., via its Indian counterpart in Bengaluru, Tesla India Motors, and Energy Pvt. Ltd., recently marked its debut in India. Ather Energy, India’s first intelligent electric vehicle manufacturer, relocated its US $86.5 million facility from Bengaluru to Hosur in 2021. Greaves Cotton also forayed into the multi-brand EV retail space under the AutoEVMart brand name. Ola Electric reportedly sold US $149.26 million in electric two-wheelers over two days, indicating market interest in electric two-wheelers in India.

The Importance of 3D Printing in EV Production

Although it might seem farfetched to think of a fully 3D printed car, thanks to advances in 3D printing materials and processes, 3D printing for EV is becoming a reality. This has stimulated a sudden surge in interest in automotive technology. Traditionally, 3D printing for automobile manufacturing was only used to develop functional prototypes. Over time, this technology has evolved to include structural design optimisation, end-user part development, and the manufacturing of specialised vehicle components. You’ll be astonished at how the 3D printing service is set to revolutionise the EV production segment.

• Rapid prototyping a reality– Depending on the complexity of the design, it can take weeks or months to print multiple versions of an automotive part. This procedure can, nonetheless, be simplified and expedited with the use of 3D printing. It offers low-cost creative options for improved visualisation.
• Enhanced manufacturing tools- Optimised product designs developed with 3D printing technology perform better and have a shorter lead time while saving time and money. Thanks to 3D printing, manufacturers can also benefit from better ergonomic tools, reducing the strain on assembly workers. A 3D printer can also develop lighter end parts for vehicles to preserve or improve part functionality.
• A vast range of materials to choose from with better thermal capabilities– Having a wide range of AM materials to choose from opens the door for automotive manufacturers to transition away from metal components in favour of polymers. Moreover, AM materials have tremendous thermal capability, which is especially critical for EVs.
• Light-weighting made possible– 3D printing has made light weighting possible, allowing for improved vehicle performance without compromising structural stability. New materials have aided in improving the process’s efficiency. Lightweight parts created through material replacement, downsizing, and part consolidation lower resource costs and enhance production efficiency.
• A permanent solution to spare parts issue- By using a 3D printing solution, manufacturers can produce all the components they need to maintain as digital copies, minimising the need for obsolete stock. In theory, a spare part could be generated on-site at the convenience of the customer, enabling easy access to 3D print in India automotive spares.
• Creation of customised complex parts: Luxury EV manufacturers can create sophisticated, customisable components for their clients by integrating digital technology and traditional production processes that are otherwise not available in the usual inventory.

The Way Ahead

Electric vehicles are the future of mobility, and India has the potential to become a worldwide deployment zone for the world’s EV demands. And to make this happen, the government would need to recruit more private investment to significantly enhance EV adoption and position India as a value-chain partner globally.