Abilities India Pistons & Rings (AIPL), manufacturer of pistons, piston rings, gravity casting, pressure die casting, and coatings, has been granted its second patent for a High-Pressure Die Casting (HPDC) process for lightweight piston manufacturing.
This innovative process is set to reduce the weight of two-wheeler (2W) and three-wheeler (3W) pistons by 10-15%, leading to substantial aluminium savings of 307.5 tonne annually based on the current production of 20 million 2W/3W vehicles.
By 2030, these savings are projected to increase to 461.25 tonne annually, with corresponding carbon emission reductions of 920 tonne per year now and 1,380 tonne per year by 2030.
Traditionally, pistons for gasoline and diesel engines are produced using the Gravity Die Casting (GDC) process, which is optimised for mass production but limited by thicker wall thicknesses and higher machining allowances. However, AIPL’s HPDC process revolutionises piston manufacturing by subjecting molten metal to high pressure within a mould, achieving intricate contours and desired geometry with minimal machining requirements. This innovation addresses stringent emission regulations for both 2-stroke and 4-stroke engines, meeting the automotive industry's evolving needs for lightweight, high-performance components.
In FY24, the company achieved a revenue of INR 128 crore and is poised for significant growth, aiming for a revenue of INR 225 crore in FY26. The company also hopes to increase its EBITDA from 14% in FY24 to about 16% in FY26. To support this growth, it intends to double its R&D team and allocate 3% of its revenue to research and development. The current manufacturing facility spans across five acres with a built-up area of 14,153 square meters, with plans to expand by an additional 3,000 square meters in FY25/26, involving an investment of INR 20 crore, supplementing the INR 17 crore invested in FY24.
Sunil Arora, Chairman and MD of AIPL, said, 'Our second patent underscores our unwavering commitment to innovation and sustainability in automotive manufacturing. This milestone reinforces our position as leaders in sustainable and efficient solutions for the global mobility domain.'
Tushar Arora, Jt. MD & CEO of AIPL added that by reducing piston weight, the company is enhancing fuel efficiency and engine performance while also cutting down on material usage and carbon emissions.
Also Read:
Abilities India Secures Patent For Piston & Cylinder Coating Technology