Abilities India, a Pistons, Piston Rings, Gravity Casting, Pressure Die Casting, and Coatings manufacturer, recently received the grant of its second patent for its High-Pressure Die Casting (HPDC) process for lightweight piston manufacturing. This automotive component is expected to reduce the weight of two-wheeler/three-wheeler pistons by 10-15 per cent. We spoke to the Chairman and Managing Director of Abilities India Pistons & Rings, Sunil Arora to know more about the product and company's future plans.
Here are the excerpts:
Q. Could you elaborate on the significance of your newly granted High-Pressure Die Casting (HPDC) patent and how it differentiates from traditional casting methods?
The High-Pressure Die Casting (HPDC) patent represents a significant advancement in the manufacturing of lightweight pistons. Traditional methods, such as Gravity Die Casting (GDC), are effective for mass production but come with limitations like thicker wall thicknesses and higher machining allowances. Our HPDC process addresses these challenges by applying high pressure to molten aluminium metal with hypereutectic silicon within a mold, achieving intricate contours and desired geometries with minimal machining requirements. This results in pistons that are lighter, stronger, and more efficient, which will help meet India’s stringent emission regulations and enhance engine performance.
Q. What challenges did Abilities India face in developing this HPDC process, and how were they overcome?
One major hurdle was achieving precise control of pressure and temperature to ensure consistent quality and performance. We tackled this through rigorous R&D, extensive testing, and collaboration with industry experts. Additionally, we invested in state-of-the-art equipment and trained our workforce to handle the new technology. Domestically, we have already been collaborating with leading Indian OEMs to integrate this technology into their manufacturing processes, supporting the self-reliance goals of the industry. We are also focusing on expanding our export markets by showcasing the superior performance and environmental benefits of our HPDC pistons to global OEMs.
Q. Can you provide specific examples of how the HPDC process improves the performance and efficiency of pistons compared to traditional methods?
The HPDC process significantly enhances the performance and efficiency of pistons and therefore engines in several ways. The reduced weight of the pistons by 10-15 per cent—translates to improved fuel efficiency and lower overall emissions. These improvements are particularly beneficial for our industry, where there is a growing demand for lightweighting and high-performance auto components. Additionally, during the manufacturing process, precise control over the casting reduces material defects and saves aluminium, leading to pistons with higher structural integrity and durability while significantly reducing material costs. This results in better thermal conductivity and higher strength, which are critical for high-performance engines.
Q. How do you plan to position Abilities India to take advantage of the projected increase in demand for lightweight, high-performance automotive components?
We are focusing on three key strategies: innovation, expansion, and collaboration. We continue to invest heavily in R&D to develop advanced materials and processes that meet the evolving demands of the automotive industry. Second, we are expanding our manufacturing capabilities to increase production capacity and cater to the growing demand. Lastly, we are strengthening our partnerships with leading OEMs globally to integrate our technologies into their product lines, ensuring that we remain at the forefront of industry advancements.
Q. What factors contributed to Abilities India's significant revenue growth in FY24, and how do you plan to achieve the projected revenue of Rs. 225 crore in FY26?
Several factors contributed to our significant revenue growth in FY24. Key among them were the successful commercialisation of our patented technologies, increased demand for our high-quality products, and our strategic partnerships with leading OEMs. Looking ahead, we plan to achieve the projected revenue of Rs. 225 crore by further leveraging our patented technologies, expanding our market reach, and continuously improving our product offerings. We also plan to double our R&D team and increase our investment in innovative solutions to maintain our competitive edge. Several new OEM customers in India & overseas are testing our samples & we expect commercial production to commence in phases that will help us to achieve our targeted revenue.
Q. What specific areas of research and development are you focusing on to stay ahead in the industry?
Our R&D efforts are focused on several critical areas. We are developing new materials and coatings that enhance the performance and durability of our products. For example, our recent patent for revolutionary piston and cylinder coating technology reduces friction, wear, emissions, and fuel consumption. We are also working on adapting our products for alternative fuels like ethanol blends and hydrogen, which are crucial for the future of sustainable mobility. Additionally, we are utilising advanced simulation software to optimise our casting processes and product designs.
Q. Can you provide details about the planned expansion of your manufacturing facility and how this will support your growth objectives?
We are expanding our manufacturing facility by an additional 3,000 square meters in FY25/26, with an investment of Rs. 20 crore. This expansion will include state-of-the-art equipment and advanced manufacturing technologies to increase our production capacity and efficiency. The additional space will also support our growing R&D activities, enabling us to develop and test new products more effectively. This expansion is crucial to meeting the increasing demand for our products and achieving our projected revenue and growth targets. A new facility will soon be planned for further growth impetus beyond 2026.
Q. Can you share any recent examples of any collaborations with OEMs that have led to significant advancements in your product offerings?
a. Electroless Nickel coated pistons were painstakingly developed over a period of 3+ years with the timely co-operation & guidance by Yamaha, Japan for their scooter plant in Chennai. Commercial production commenced in October, 2023.
b. High Pressure Die Cast pistons with a lug were developed in collaboration with STIHL USA & Brazil over a period of 2+ years & both are now in active commercial production.
c. Electroless Nickel coated aluminium cylinders have been developed as 100 per cent import substitution for Wabtec India again with the active collaboration of their European principals & commercial production is now on the anvil.
We have patents for all three products.
Q. How do you foresee the automotive component industry evolving over the next five years?
Over the next five years, the automotive component industry is likely to witness significant transformations driven by advancements in technology and increasing environmental regulations. We anticipate a growing demand for lightweight, high-performance components that help enhance fuel efficiency and reduce emissions. The shift towards cleaner technologies will also drive innovation in materials and manufacturing processes. Companies that invest in R&D, adopt sustainable practices, and collaborate closely with OEMs will be well-positioned to lead in the industry. Moreover, we believe that hydrogen ICE will become a reality over the next five years & EV will be A form of mobility & not THE means of mobility.
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