ICONICS announces its official name change to Mitsubishi Electric Iconics Digital Solutions (MEIDS), marking a bold step in its evolution. Backed by Mitsubishi Electric Corporation, MEIDS continues to lead in SCADA automation, digitalisation, and smart, sustainable buildings with expanded resources and global reach. 

ICONICS, a SCADA industrial automation, digitalisation, and smart buildings software provider, changes to Mitsubishi Electric Iconics Digital Solutions (MEIDS). This milestone is a step forward in the company’s integration into the Mitsubishi Electric Corporation family and helps showcase its continued evolution into a global leader in digital solutions and transformation. 

Mitsubishi Electric has supported ICONICS’ growth for over a decade, culminating in a full acquisition in 2019 and continued collaboration as part of the Mitsubishi Electric Group. This name change is a recognition of our technological excellence, customer commitment, and position as Mitsubishi Electric’s global SCADA automation and digitalisation platform. 

The Meaning Behind the Name 

The name unites the global strength of Mitsubishi Electric—a trusted leader in industrial and digital innovation; the legacy of ICONICS as a pioneer in SCADA automation and digitalisation software; and a growing portfolio of digital solutions for industrial operations, infrastructure, and smart, sustainable buildings. These elements combine to deliver the software, services, and next-generation technologies that drive performance and long-term impact.

This foundation enables MEIDS to set the gold standard in SCADA automation and digitalisation, reinforcing our commitment to innovation, efficiency, and customer success by empowering industries worldwide. 

A Strong Heritage, A Stronger Future 

While the name has changed, the mission and entrepreneurial spirit of the company remain steadfast, delivering groundbreaking SCADA automation, smart buildings software, and digitalisation solutions with exceptional customer service. Major innovations across core product families, in particular GENESIS (also referred to as GENESIS version 11), are underway. By retaining “Iconics,” the company honors its rich legacy of innovation, while “Digital Solutions” reflects expansion into advanced services, intelligent technologies, and the future of industrial digitalisation. 

Ted Hill, President & CEO of Mitsubishi Electric Iconics Digital Solutions, emphasises the significance of this transition, “This is more than a name change—it’s a declaration of who we are and where we’re headed. With the backing of Mitsubishi Electric and the agility of ICONICS, we are uniquely positioned to drive the future of industrial automation and smart, sustainable infrastructure. Our customers can expect the same cutting-edge solutions and world-class support, now with even greater resources and opportunities.” 

The Best of Both Worlds: Innovation with Global Strength 

Mitsubishi Electric Iconics Digital Solutions brings together the innovation and agility of a tech pioneer with the strength and scale of a 100-year-old global leader. The customers can benefit from deep integration within Mitsubishi Electric’s ecosystem—spanning industrial automation and digitalization, intelligent infrastructure, and smart building and energy management solutions. With Mitsubishi Electric ranked among Forbes’ Top 200 World’s Best Employers and Top 400 World’s Largest Companies, this alignment strengthens their ability to deliver cutting-edge solutions worldwide. 

Continued Bold New Steps 

This transformation cements our role as Mitsubishi Electric’s global platform for SCADA industrial automation, digitalisation, and smart building and workplace solutions—reaffirming our commitment to customers, partners, and employees. Aligned with this vision, MEIDS recently launched our flagship GENESIS platform and continues to release quarterly updates to our Intelligent Building Software Stack (IBSS). This is more than a new name—it’s the next chapter of innovation, integration, and industry leadership. 

This year, the Salzgitter Group is once again putting its green steel brand SALCOS at the centre of its appearance at HANNOVER MESSE. But personnel recruitment will also play a role.

This year, the steelmakers of Salzgitter AG are presenting themselves at HANNOVER MESSE under the motto “A new way of thinking for a new industry – #hierpassierts”. The aim is to emphasise the company’s leading role in the circular economy and in the sustainable restructuring of the economy.

At the Salzgitter AG stand C62 in hall 13, everything will once again revolve around the group’s own green steel brand SALCOS. With the SALCOS transformation programme of the same name, the Salzgitter Group is in the process of gradually converting its steel production to hydrogen-based processes in order to establish almost CO₂-free steel production. In addition to a wealth of information about Salzgitter AG, the products of its individual subsidiaries and the SALCOS transformation programme, this year’s trade fair stand will also be hosting a presentation by the Hydrogen Campus Salzgitter e.V., which is committed to promoting and developing pioneering hydrogen technologies.

In addition, the Salzgitter AG Human Resources department will be represented throughout the entire trade fair to provide interested visitors with information about the numerous career opportunities in the Salzgitter Group.

Frank Seinsche, responsible for trade fairs at the Salzgitter Group: “As pioneers in the industry, we are demonstrating at our trade fair stand how hydrogen-based steel production will enable the production of virtually CO2-free steel in the future. In addition, steel plays an important role in the development of a hydrogen infrastructure in Germany. The group will use large quantities of hydrogen for production in the future, is currently building its own large electrolyser and offers suitable pipes for the development of hydrogen networks.”

The Alberta Machine Intelligence Institute (Amii) highlights its expertise in reinforcement learning (RL) at HANNOVER MESSE 2025. The institute helps businesses integrate AI, ML, and RL into operations, offering competitive edge in logistics, oil & gas, and manufacturing.

As a leader in AI-driven industrial solutions, Amii is home to Turing Award winner Richard S. Sutton; pioneering work on RL forms the foundation of modern artificial intelligence. The institute helps businesses integrate AI, ML, and RL into their operations, equipping them with proprietary models and in-house AI expertise.

Industries are in the early stages of RL adoption, and companies partnering with Amii now can gain a competitive edge. Key applications include:

• Logistics – Optimising supply chains and delivery routes for peak efficiency.
• Oil & Gas – Enhancing resource allocation for sustainable and efficient energy production.
• Manufacturing – Streamlining industrial processes to reduce waste and boost productivity.

Inspired by AI breakthroughs such as AlphaGo and DeepSeek R1, Amii helps businesses achieve transformative results. The institute is actively seeking international partners to expand the impact of RL-driven innovation across industries.

Shree Cement has announced the commissioning of its new grinding unit in Etah, Uttar Pradesh. The unit has an annual capacity of 3 million tonnes per annum. The investment of approximately ₹850 crore is expected to create over 500 direct and indirect employment opportunities.

Shree Cement, one of India’s leading cement manufacturers, announced the commissioning of its new grinding unit in Etah. With an annual capacity of 3 million tonnes per annum (MTPA), the Etah unit from Shree will be one of the largest grinding units in the region, adding to the growth journey of the state of Uttar Pradesh. The project, entirely funded through internal accruals, entails an investment of ~₹850 crore and is expected to create more than 500 direct and indirect employment opportunities.

Neeraj Akhoury, Managing Director, Shree Cement, said, “At Shree Cement, we are committed to supporting Uttar Pradesh’s rapid infrastructure and housing development. Our manufacturing units also contribute to a sustainable future for local communities by creating job opportunities, establishing educational facilities and improving infrastructure.”

The strategic location of the unit, closer to the railway infrastructure, enables cost-effective transportation of raw materials from Rajasthan, while cement dispatch will leverage roadways and railways for optimal distribution. A newly constructed road provides direct highway access, enhancing transportation efficiency and streamlining logistics.

The Etah plant will serve as a model for sustainability, featuring zero-waste operations, air-cooled screw compressors to minimize water consumption and advanced filters to ensure minimal environmental impact. Additionally, the plant has collaborated with an adjoining Jawaharpur Thermal Power Plant to consume its 100% fly ash waste – about 5000 tons per day, enhancing operational efficiencies. In line with Shree Cement’s commitment to green energy, a solar installation is planned within the next 2-3 years.

The Etah grinding unit is equipped with cutting-edge German technology, not only for the core operational part but also in advanced pollution control systems, including the Mill Bag House with epoxy cages. This technology ensures exceptional efficiency in pollution control, reducing dust emissions to levels well below the prescribed norms and minimising environmental impact. The plant has 100% covered storage for raw materials to ensure the highest standards of safety and quality. Additionally, advanced filters maintain air quality, reinforcing Shree Cement’s commitment to a sustainable and pollution-free environment.

Technological innovations at the plant include an AI-based bag counter system for precise inventory management, a laser-based online particle size analyser for optimised cement quality, and enhanced safety measures, including thermal sensors and rear door limit switches in HT panels. The plant also features an industry-first waggon tippler system, adhering to the latest Railway RDSO guidelines, with German-designed twin hybrid Samson feeders that reduce power consumption, lower lift, save time and eliminate water seepage issues. This state-of-the-art facility exemplifies a commitment to innovation, excellence and sustainability in the cement industry.

As part of its CSR initiatives, Shree Cement will also focus on infrastructure development and providing education in the nearby village of Nigoh Hasanpur, benefiting 2500 residents.

Shree Cement Limited is a leader in sustainability, operational efficiency and innovation. Committed to eco-friendly building solutions, the company utilises synthetic gypsum, maintains 6x water positivity and harnesses multiple fuel sources, including waste materials. It also advances sustainable transportation by increasing railway usage and adopting electric and CNG vehicles.

The brand portfolio offers a range of premium products, including Bangur Magna for solid concrete, Bangur Roofon for solid roofs, and Bangur Marble for solid bright homes. It also features Bangur Shree Jungrodhak for rust resistance, Bangur Powermax for powerful crack resistance and Bangur Rockstrong for rock-like strength.

The manufacturing facilities are incomplete without metrology instruments, and now we have metrology systems that integrate automated CMMs and vision systems to reduce human error.  Venkat Srinivasan, COO of Trimaster Metrology LLP & Trimos India Pvt Ltd, shares that real-time measurement and feedback streamline production to provide consistent quality and faster inspections for modern manufacturing demands.

Metrology ensures that parts are made to the correct specifications. How are you using automation technology to enhance precision measurement in modern manufacturing?

We use automation technology to enhance precision measurement in metrology. Automation has revolutionised precision dimensional measurement in modern manufacturing. Automated CMMs and vision measuring systems have taken metrology ahead. These systems execute repetitive tasks with minimal human intervention, dramatically reducing the potential for human error and ensuring consistently accurate results. This strengthens the reliability of measurements and increases the output. The ability to perform faster inspections directly translates to improved production efficiency, allowing manufacturers to optimise processes and meet the demands of today’s fast-paced environment.

What are the latest advancements in online metrology and real-time quality control systems? What innovations has Trimaster Metrology proposed?

Online Metrology takes measurements directly to the point of production. By integrating precise measurement systems like our Trimos C4 instrument into the manufacturing line, users can reduce lead times and minimise errors in measurement processes. Our Trimos C4 CNC CMM does real-time feedback, instantly relaying data to the machining centre for accurate, online measurement and automated error correction. This seamless integration ensures higher efficiency, better quality control, and a more streamlined production process, thus making manufacturing more responsive than ever.

What challenges do you face in achieving micron-level accuracy, and how can they be addressed?

Environmental factors like temperature and vibrations, instrument limitations in calibration and resolution, material properties affecting measurements, human error, and contamination issues challenge achieving micron-level accuracy in metrology. We address these issues by strongly investing in controlled environments, high precision , and quality instruments with automated systems. We establish robust procedures, utilise advanced software, and maintain rigorous calibration and test schedules. Continuous improvements give us optimum performance and reduce errors.

How do metrology solutions contribute to reducing waste and improving manufacturing?

Our solutions drive sustainability in various industries. We deliver precise instruments according to the user’s requirements and also reduce inspection time. We also promote reuse through refurbished instruments. Regular servicing and calibrating instruments provide accurate measurements, optimise instrument usage, and decrease energy consumption through process enhancements, ultimately extending product lifespans. This focus on preventing rework and efficient resource allocation makes our metrology products a key contributor to a more sustainable and environmentally responsible manufacturing process.

What are some of the latest trends in portable and handheld metrology solutions, and how are they benefiting shop floor applications?

The latest trends in portable and handheld metrology solutions are revolutionising shop floor applications by offering greater flexibility, speed, and accuracy. Our 3D portable arms and height gauges empower manufacturers to perform on-site inspections quickly and accurately on the shop floor, thus streamlining workflows, reducing downtime, and enhancing real-time quality control.

Portable CMMs and handheld instruments, such as 3D portable arms and Trimos C4 CNC CMM, are incorporated into automated measurement routines. They can reduce operator dependency and minimise human error, speeding up inspection processes and ensuring consistent results.

Wireless data transfer and remote-control capabilities, like those in our Trimos height gauges, allow seamless integration with existing manufacturing systems. This facilitates real-time data sharing and analysis, allowing for immediate process adjustments.

Lighter, more compact designs and improved ergonomics make handheld devices easy to use in confined spaces and for extended periods, enhancing operator comfort and productivity.

What is the next big leap in industrial metrology that will transform manufacturing in the next five years?

Looking ahead, the next five years will witness a transformation in dimensional metrology with AI and advanced sensor technology.  Specifically, the widespread adoption of AI-powered, real-time, in-process measurement will be pivotal. The manufacturing lines will have dimensional metrology as an integral production process.  Sensors embedded within the instruments will continuously monitor dimensions, and AI algorithms will analyse this data in real-time. This will help systems to detect even minute deviations from specifications as they occur. The result will be self-correcting manufacturing lines that operate with unprecedented precision and efficiency. This will improve product quality and reduce costs while providing complex and innovative products.

The pharmaceutical and food & beverage (F&B) sectors are crucial because they are directly connected to human health. Therefore, ensuring end-to-end traceability and transparency is essential. Advanced traceability solutions will enhance the reliability of the Indian pharmaceutical and F&B sectors, ultimately boosting trade and exports. This article discusses the various solutions that manufacturers can implement.

Johnson & Johnson’s talcum powder was a household name in India until the controversy caused the Indian government to order Johnson & Johnson to recall specific pharmaceutical-grade talc batches in 2019. Concern was raised that some batches of baby talcum powder might contain cancer-causing asbestos. Advanced batch-level tracking helped authorities identify affected products quickly, preventing further sales. J&J used digital records and supplier traceability to verify raw material sources and prevent future contamination.

Also, our beloved Maggi Noodles faced a nationwide ban after the Food Safety and Standards Authority of India (FSSAI) found that certain batches contained lead levels above the permissible limit (2.5 ppm) in 2015. The controversy erupted when tests conducted by the Uttar Pradesh FDA found 17.2 ppm of lead in a sample, nearly seven times the legal limit. Additionally, the product was accused of containing MSG (monosodium glutamate) without proper labelling. Nestlé had to trace back affected batches using its internal tracking system. Nestlé used barcodes and batch numbers to identify the manufacturing plants involved quickly.

Last year, India’s Pharmaceutical Export Compliance and traceability Mandates were implemented. The Indian government made QR codes mandatory for the top 300 brands of pharmaceutical drugs to improve traceability. This was in response to increasing counterfeits and global export requirements. Sun Pharma, Cipla, Aurobindo, and Biocon integrated 2D barcodes on medicine strips and packaging. This allowed end-to-end tracking from manufacturing plants to end consumers, boosting India’s reputation as a reliable pharma exporter.

Challenge

A major challenge in today’s manufacturing sector is the lack of traceability at a large scale. Traceability refers to tracking and documenting a product’s journey through the supply chain. Fragmented supply chains, counterfeits, and inconsistent technology adoption further complicate this issue.

While some large companies have explored blockchain technology to enhance transparency, the results have varied. Many modern manufacturing plants have automated systems that record every production stage; however, it is still unclear how many advanced plants exist in India. The vision of a “Viksit Bharat” (Developed India) is closely linked to the growth of Micro, Small, and Medium Enterprises (MSMEs).

Small enterprises constitute more than half of India’s food supply chain but often lack effective tracking systems. To move forward, smaller organisations should embrace digital tools, standardise processes, and invest in training their workforce on the importance of proper documentation and tool adoption.

Solutions

Traceability is becoming increasingly essential in pharmaceutical drug manufacturing. Regarding large manufacturing sites, traceability and audit trail mapping are necessities, especially for companies involved in large assembly manufacturing. These companies need a comprehensive IT-OT setup that is well-mapped out and audited. At any given time, they should be able to trace any batch output to a specific scenario with an accurate timestamp. When we asked Kaushik Pal, Head of Systems Integration Services, Business Unit, Tata Elxsi, what they do for traceability, he shared, “To facilitate traceability, we utilise computer vision technologies, such as our IP or IRIS systems, to track various processes and assembly nomenclatures. This approach pinpoints the bad batch produced within a specific timeframe and assembly line rather than discarding the day’s work or batch output. By identifying and addressing the problematic batch, we can maintain return on investment (ROI)  and limit potential losses for manufacturers. We provide traceability solutions and also partner with ecosystem providers to enhance traceability. This aspect has become a critical part of our content manufacturing focus.”

Parminder Singh, Head of D&M Business at Autodesk India & SAARC, shares that a comprehensive suite of tools designed to support manufacturers in ensuring traceability can be incorporated within operations. Product Lifecycle Management (PLM) solutions can help manufacturers track and manage the entire lifecycle of a product, from inception through engineering design and manufacturing to service and disposal. This ensures that every stage of the product development process is well-documented and traceable. Digital Prototyping tools allow manufacturers to create and test digital prototypes of their products. This reduces the need for physical prototypes and ensures that all design changes and iterations are recorded and traceable. Data management securely stores and manages the engineering data. A version control factor ensures that all changes to design files are tracked and traceable. 

Manufacturing Execution Systems (MES) solutions help manufacturers track production processes in real-time. This includes monitoring the usage of materials, labour, and equipment and ensuring that all aspects of the manufacturing process are recorded and traceable. Quality Management ensures that any defects or issues are recorded and can be traced back to their source. Supply Chain Management tools can help manufacturers manage their supply chains by providing visibility into the sourcing and movement of materials. This ensures that all materials used in production can be traced back to their origin. 

Scanning Solutions

Technologies such as RFID, barcodes, and QR codes are evolving to enhance traceability in manufacturing.

Sameer Gandhi, MD, OMRON Automation, India, shares how RFID technology is integrated with the Internet of Things (IoT) and cloud computing, facilitating real-time data collection and analysis. Advances in the miniaturisation and cost reduction of RFID tags have made widespread use feasible, enabling detailed tracking of individual components and products. Improvements in RFID reader technology have enhanced read range and accuracy, ensuring better monitoring throughout the production process.

Barcodes are transitioning to 2D versions like Data Matrix and QR codes, which can store more information and are more resilient to damage. Modern barcode scanners have also advanced, offering faster and more accurate readings from various angles and distances, enhancing inventory management and quality control. These scanners integrate with digital systems for real-time tracking and data analysis, providing manufacturers valuable insights into production processes and supply chain management.

QR codes have significantly increased data capacity compared to traditional barcodes, making them ideal for detailed product tracking and traceability. Initially used for tracking automobile parts, they are widely adopted across various manufacturing sectors. They provide additional information to users, such as product details, usage instructions, and safety information, thereby enhancing transparency and traceability.

Advanced technologies will drive ROI for investors and bring transparency, resulting in greater trust in the brand’s reliability. Traceability and accountability can boost consumer confidence. Improved traceability and quality control can elevate export standards, expanding trade opportunities and strengthening the brand’s position in global markets.

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Kaushik Pal, Head of Systems Integration Services, Business Unit, Tata Elxsi

“Traceability is crucial for manufacturing efficiency. Advanced computer vision systems can help users pinpoint defects in real-time, ensuring precise batch tracking, reducing waste, and maximising ROI for manufacturers.”

Parminder Singh, Head, D&M Business, Autodesk India & SAARC 

“With Product Lifecycle Management, digital prototyping, and real-time production tracking, manufacturers can ensure complete traceability, enhancing accountability, compliance, and quality at every stage of the manufacturing process.”

Sameer Gandhi, MD, OMRON Automation, India

“Technologies like RFID, barcodes, and QR codes are major tools in traceability as they can enable real-time tracking, enhanced accuracy, and better insights. This improves efficiency, product quality, and customer satisfaction in manufacturing.”

The automotive and aerospace industries constantly seek ways to reduce weight, cut costs, and improve fuel efficiency. Innovations in technology—led by additive manufacturing and 3D printing—make these endeavours possible by printing lighter, more efficient designs. Industry leaders share their insights on the materials driving the creation of lightweight components for next-generation aircraft.

Ever wondered how IndiGo Airlines keeps its fares so low? It’s all about shedding the extra weight—literally! The airline is famous for its all-female crew on certain flights, and this is not a representation issue but because, on average, they weigh 15–20 kg less per person than their male counterparts, saving thousands of litres of fuel annually.

IndiGo also skips the heavy ovens, serving only pre-packaged meals, and ditches glass bottles for paper glasses. The seats are also ultra-light. In 2015, IndiGo lobbied with the aviation regulator to become the first airline to launch an Electronic Flight Bag, reducing 25 kg of paper on its planes by replacing paper charts/manuals with iPads. This reduces weight & reduces their carbon footprint annually by ~2500 tons. Every kilo saved means less fuel burned, lower costs, and cheaper tickets —that’s smart flying!

Less is more—IndiGo Airlines proved this by registering a ₹8,172.4 crore profit in 2024. The lighter the aircraft, the lower the fuel consumption, leading to higher savings and reduced pollution—a win for both business and the environment.

These innovations cannot be adopted by all airlines. Therefore, aircraft and component manufacturers focus on making the entire aircraft lighter to reduce fuel consumption and save costs.

Materials for lightweight

In India, blade manufacturing is on the rise, and there is an increasing demand for microscopy-related analyses, focused on coatings. Multiple coatings are applied to enhance the metal’s ability to withstand high temperatures and meet specific grain requirements. As a result, Indian companies are seeking a deeper understanding of the raw materials and processes involved.

Wings, mechanisms, and turbine systems are designed efficiently for optimal energy yield. The manufacturer manages the shaping operations, ensuring that the design is accurately reproduced during production.

Adimoolam Thirumal, Product Manager – Milling Solutions at EMUGE-FRANKEN India Pvt. Ltd., shares that this process begins in the design stage, where requirements define the initial concepts. We can consider how to work with materials, which involves a thorough evaluation based on previous references and records. This is an ongoing improvement process, including methods of production.

He shares, “Cutting high-strength, heat-resistant superalloy (HRSA) materials to obtain the required shapes and sizes can be challenging. However, with 3D printing, we can develop more effective and efficient methods to reduce weight while adding significant value.

As technology continues to evolve, we are seeing new materials, such as composites, that are more versatile for shaping and production, and that can also be recycled. This could be a game-changer. We must focus on the specifics of each part to ensure they meet the drawing requirements, while also understanding the various intermediate groups, the technologies involved, and the manufacturing challenges we face.”

One of the exciting developments in additive manufacturing is lunar and Martian regolith, or locally available materials on these celestial bodies, for 3D printing. Researchers also focus on functionally graded materials (FGMs), which offer varying properties within a single component. Many universities are making strides in this field, exploring smart materials that can function as sensors and structural components. Additionally, some materials generate electricity when exposed to a magnetic field, further expanding the possibilities when combined with 3D printing innovations. Overall, significant advancements in material science are shaping the future of manufacturing.

Composite materials for aerospace

Composites are crucial in aircraft technology, enabling lighter and more durable nacelles, which house aircraft engines. The nacelle comprises an inlet that ensures laminar flow for better aerodynamic performance. It has a fan cowl that provides access for maintenance on coolers and lines. Although not required by the FAA, a thrust reverser delivers 10% to 30% reverse thrust upon landing and operates at high temperatures (1500-1600°F).

Composites typically can’t withstand temperatures over 250°F without thermal blankets, while titanium and nickel-based superalloys are used in high-temp nacelle sections.

Hardik Someshwar, CEO of AeroDef Nexus, shares a tale of how, in 1990, an aerospace company nearly faced shutdown but was revived by adopting Total Productive Maintenance (TPM) and Lean practices. This pivot led to securing the 787 program, recognised for its advanced composite structures and technologies, including the 787-8, 787-9, and 787-10 variants with significant engine requirements from GE (GEnx) and Rolls-Royce (Trent 1000).

Most aerospace composites are now made from carbon fibre, with sourcing still dominated by Japan, the U.S., and Europe. Southeast Asia, including India, is emerging in the supply chain, with major players like Tata Advanced Systems (TASL) and Hindustan Aeronautics Limited (HAL).

Current challenges include long cycle times, difficulty sourcing raw materials and obtaining aerospace-grade certifications within India.  We must enhance our composite production capabilities and establish reliable raw material sources to compete globally. Maintaining high standards in plant operations is essential, with organisations like the National Aerospace Laboratories (NAL) playing a vital role in composite research. For significant advancements, scaling up production is crucial.

Additive Manufacturing and 3D Printing

Additive manufacturing allows the processing of materials that are prone to cracking. By utilising electron beam technology and powder-based techniques, working with materials that typically crack when cast becomes feasible. This technology opens up new possibilities for exploring alternative materials. Aerospace leaders such as Boeing and Airbus have conducted detailed studies and life cycle analyses focusing on sustainability. Considering the carbon footprint associated with 3D printing a component is essential while evaluating its entire life cycle.

Akshatha Dayananda, Addwize Leader & Manager at Wipro 3D, shares, “Additively manufactured components are lighter, more complex, and exhibit improved performance. For instance, a turbine blade that previously needed to be replaced after 1,000 hours can now last for up to 3,000 hours. Research and evidence suggest that over the life cycle of these components, they prove to be more sustainable and contribute to fuel savings in the short term. In the long run, significant cost savings can be achieved.”

Different additive manufacturing technologies have varying levels of maturity. Laser powder bed fusion (LPBF) and electron beam powder bed fusion (EB-PBF) are among the most mature. A notable example is GE’s case study on the LEAP fuel nozzle tips—over 100 million of these parts have been manufactured and are currently in service within GE’s LEAP engines. While this achievement isn’t widely discussed, it highlights that thousands, and even millions, of metal components have already been certified and are actively used in aircraft.

Additionally, many components, particularly ducts, are 3D printed in the interiors of civil aircraft. These ducts are designed to maintain laminar flow and ensure easy replacement, making additive manufacturing a practical solution for such applications.

Manoj Sundaram, Head of Business Development, ZEISS India, Industrial Quality Solutions, has observed the production of small flanges and manifolds through additive manufacturing. For example, blades have been manufactured using this technology, achieving weight reductions of 10, 20, or even 30 grams. Over a year, with an aircraft flying approximately 300 times, these weight reductions can significantly impact its carbon footprint. Each gram of weight reduction offers multiple benefits, especially long-term operational efficiency.

While creating lightweight components is relatively straightforward, it is essential to ensure that they meet aerospace industry safety standards. This is where advanced quality systems play a vital role.

When a manifold is produced using additive manufacturing, its quality can be guaranteed by advanced technologies such as X-ray inspection. Even the smallest additively manufactured parts can be qualified through electron microscopy. Lightweight designs through additive manufacturing enhance performance while promoting sustainability and reducing the carbon footprint. Boeing’s noteworthy examples illustrate these advancements.

Breakthrough technologies

The evolution of technology is underway, with advantages and disadvantages to consider. We are witnessing significant progress as the digital world adapts to new concepts. One field is materials science.  The focus is on safety factors, and the validation process is critical. If we can shorten the evaluation and validation timelines, it will lead to numerous advancements.

Numerous technologies have been developed for measuring lightweight materials. Additive manufacturing is one approach to achieving lightweight structures, which can be accurately assessed using X-ray computed tomography (CT) technology. Additive manufacturing presents challenges, such as achieving a good surface finish. However, these attributes can be measured non-destructively. Additionally, the concept of digital twins is expanding. Digital twins can measure external surfaces and also assess internal structures. All these technologies allow manufacturers to achieve lighter vehicles while maintaining performance and sustainability, paving the way for a smarter, more fuel-efficient future in aviation.

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Manoj Sundaram, Head of Business Development, ZEISS India, Industrial Quality Solutions

“Every gram saved in aerospace lightweight translates into fuel efficiency and reduced carbon footprint. Additive manufacturing, X-ray technology, and digital twins ensure precision, safety, and sustainability in next-generation aircraft manufacturing.”

Adimoolam Thirumal, Product Manager – Millings Solutions, EMUGE-FRANKEN India Pvt. Ltd.

“Aerospace manufacturing is driven by material science, digital adaptation, and additive manufacturing. The challenge lies in balancing innovation with safety, assuring efficient validation, and accelerating the journey from concept to execution.”

Akshatha Dayananda, Addwize Leader & Manager, Wipro 3D

“Additive manufacturing is changing the face of aerospace manufacturing with crack-resistant materials, extended part lifespans, and sustainability benefits. Digital integration, AI-driven monitoring, and traceability ensure precision, reliability, and confidence in every 3D-printed component.”

Hardik Someshwar, CEO, AeroDef Nexus.

“Companies must invest in future technologies and raw material sources, processes, and qualifications to achieve large-scale composites.”

End-to-end traceability has made manufacturing processes more reliable. Sameer Gandhi, MD of OMRON Automation India, shares how they assist manufacturers with seamless traceability by integrating real-time data capture and compliance assurance into their production systems.

What challenges do manufacturers face in achieving seamless end-to-end traceability? How is OMRON placed to address them?

Manufacturers face challenges in achieving end-to-end traceability, such as data integration, technology compatibility, costs, regulatory compliance, and data security. Integrating consistent and accurate data from various sources is complex. Different technologies and standards hinder seamless interoperability. Also, implementing traceability systems is expensive and time-consuming, especially for SMEs. Compliance with varying regulations and protecting sensitive data from cyber threats are a few more significant concerns.

We are well-positioned to address these challenges with our comprehensive traceability solutions. Omron offers end-to-end traceability solutions that integrate seamlessly with existing manufacturing systems, including code reading, RFID technology, and laser marking for efficient product identification and tracking. Our solutions enable real-time data capture and analysis, providing manufacturers with immediate insights into their production processes and helping identify and promptly address issues. Our barcode verification and label inspection solutions confirm that all labels and barcodes meet industry standards and regulatory requirements to maintain compliance and avoid costly errors. Our traceability solutions are scalable and flexible, making them suitable for manufacturers of all sizes. They can be tailored to meet the specific needs of different industries, from automotive to life sciences. We also have expertise in implementing robust security measures to protect traceability data from cyber threats, ensuring data integrity and privacy and providing manufacturers with peace of mind.

With increasing supply chain disruptions (such as semiconductor shortages and geopolitical tensions), how can traceability technologies help manufacturers mitigate risks?

Traceability technologies, such as those offered by OMRON, mitigate supply chain risks like semiconductor shortages and geopolitical tensions by enhancing visibility, efficiency, and compliance. These technologies perform real-time tracking and comprehensive data collection, allowing manufacturers to identify and address potential bottlenecks early. Automating identification processes with RFID and barcode scanning reduces errors while integrating traceability data with predictive analytics helps with disruption forecasting and continuity maintenance.

Our traceability solutions ensure regulatory compliance and quality control by monitoring products and components at every stage. This compliance avoids legal issues and maintains market access. When supplier networks are managed effectively, and alternative sources are known, manufacturers can diversify their supply chains and reduce dependency on single suppliers. This mitigates risks associated with geopolitical tensions. However, manufacturers can take a significant amount of time to evaluate new suppliers and bring them on board. New suppliers can adopt traceability to assure customers of their processes’ robustness and quality and reduce onboarding time.

What are the cost implications of implementing advanced traceability systems, and how can businesses increase their ROI?

Investment in advanced traceability systems can give a competitive advantage by enhancing operational efficiency, product quality, and customer satisfaction.

Implementing advanced traceability systems involves initial setup costs like purchasing technology, upgrading infrastructure, and training staff, along with ongoing operational expenses for maintenance and data management. These systems can also incur indirect costs due to potential downtime and change management during implementation. However, optimising supply chain efficiency and predictive maintenance can lead to significant cost savings and improved ROI. A robust traceability system enhances product quality and regulatory compliance, reducing defects and legal issues.

Traceability systems help avoid product recalls by providing a detailed and accurate record of each product’s journey through the supply chain. This enables manufacturers to identify and isolate defective products while minimising the impact on consumers and financial losses. Efficient recall management prevents harm and protects the brand’s reputation by demonstrating a commitment to quality and safety.

Businesses can increase ROI using traceability data to make informed strategic decisions, improve customer satisfaction, and foster innovation. Providing transparency about product origins and quickly addressing issues builds consumer trust and loyalty. By transforming data into actionable insights, companies can optimise supply chain routes, select reliable suppliers, and forecast demand more accurately.

How does traceability impact regulatory compliance and quality assurance in highly regulated industries?

In highly regulated industries (like pharma), traceability systems safeguard regulatory compliance and quality assurance by providing detailed records, facilitating audit readiness, and enabling efficient recall management. It helps monitor product quality throughout production, optimise operations, and enhance supply chain visibility, building consumer trust. Traceability systems manage product recalls by swiftly identifying and isolating defective products, thus reducing potential harm and financial losses to companies. For instance, in healthcare and the food and beverage industries, traceability ensures patient safety and food safety by tracking products from production to end use, thus maintaining adherence to stringent regulations and preventing errors or contamination.

India’s manufacturing sector is advancing, driven by high-speed machining, aerospace, and electronics manufacturing. With  Ace Manufacturing Systems and Ace Designers now unified, L.S Umesh, Director, Ace Designers Ltd, Machining Centre Division, shares that their combined strength in R&D, AI, automation, and Industry 4.0 will keep them ahead in the industry. He shared the vision of this unification, which is delivering innovative, cost-effective, and customer-focused solutions.

How is Ace addressing the evolving needs of high-speed machining, and what impact does your amalgamation with AMS have on the future of manufacturing?

The industry is focused on high-speed machining. Thin-walled component manufacturing is gaining popularity, especially in sunrise sectors along with graphite manufacturing. Ace has technologies that address these needs for electronic or aerospace component manufacturing. These sectors require high-speed, high-precision manufacturing, which presents a significant challenge for all of us.

India is making strides in aerospace components and mobile manufacturing. However, for our economy to develop, we must prioritise indigenous production and support initiatives like “Make in India.”

At IMTEX 2025, we showcased at least six of our new technology products, which received enthusiastic responses from customers. We even attracted customers from the UK and USA, who expressed excitement about taking our new machines back to their countries for sale.

IMTEX is a vital platform for us to demonstrate technology, and we value the opportunity to meet our customers, whom we consider friends, all in one place with our diverse range of machines. Notably, this edition of the IMTEX marks the first participation of the unified entity as Ace Designers Limited. We are participating together as ADL rather than as separate entities. This synergy showcases our technological strengths and highlights how we work together on various products.

With Ace Designers and Ace Manufacturing Systems joining forces, how is this collaboration shaping your R&D strategy and future innovations?

If you look closely at the growth of Ace Designers and Ace Manufacturing Systems, you’ll see that we started small. It enables faster development and production. However, we have now reached a stage where both companies are exploring investment methods for R&D and other initiatives.

Historically, we faced challenges in financing our R&D efforts, but by uniting, we pool our financial resources, strengths, and knowledge. This collaboration has allowed us to establish a dedicated R&D department for our combined efforts. We have even appointed a Chief Technology Officer (CTO), bringing significant value to our R&D initiatives. We can now financially sustain a separate R&D team and have a clear vision for how this department should operate. Our focus is on delivering new technologies, ensuring we are 100% customer-focused and even anticipatory of future requirements.

To achieve this, we have also created the product manager role. This individual will identify the future needs of our customers, whether in machining, 3D printing, laser cutting, or bending technologies. In the next three to four years, we plan to evolve with new leadership roles. The impact of the R&D efforts, with our CTO’s leadership and the contributions of some of our brightest young engineers, will help us stay ahead of the competition and deliver innovative technologies that benefit our customers.

As a pioneer in Industry 4.0, how has your journey evolved from the early 2000s to the present, and how do you see its impact on modern manufacturing?”

We were among the pioneers of the Industry 4.0 movement during the early 2000s. We began with productivity monitoring, machine downtime tracking, and similar initiatives. Although the term “Industry 4.0” came into use recently, we were essentially the first movers in this space, establishing a strong foothold in the market.

Our products incorporate metrics such as Overall Equipment Effectiveness (OEE) measurements. We can integrate our technology with any product that contains a Programmable Logic Controller (PLC) or CNC controls, making our OEE measurement capabilities widely applicable. Our offerings in Industry 4.0 are designed to serve all customers, including competitors and various end users.

We are committed to continuous improvement, paying close attention to our customers’ evolving needs. Recently, we’ve noticed a significant shift among machine tool users, particularly with the new generation of manufacturers. Unlike before, when we had to advocate for these technologies, our customers now actively demand them. Industry 4.0 will enhance productivity, improve product quality, and reduce delivery times, ultimately benefiting our customers.

Please tell us about amace’s collaboration with Ace Designers to advance and make 3D printing affordable in India.

In 2018, we envisioned the potential of 3D printing and decided to collaborate with Ace Designers. The investment in this technology through partnership resulted in the formation of amace. Before developing our first product independently, we focused on understanding customer needs, which led us to begin working on application engineering.

Our 3D printing services using different materials helped us identify our customers’ challenges and pain points. We learned that simply printing a part according to customer specifications was not enough—it was essential to redesign components with a focus on strength, minimising material use, and ensuring uniform stress distribution. This engineering approach allowed us to reduce costs and weight, which is crucial in the aerospace industry, where every gram saved contributes to lower fuel consumption and overall cost reduction.

To achieve optimal results, we analyse component usage and assembly requirements and explore ways to reduce the number of parts through re-engineering, ultimately providing comprehensive solutions. While many companies have focused on R&D or rapid prototyping, few have truly scaled production using 3D printing machines. Our machines are a valuable asset for customers across different applications, including prototyping and aerospace components.

Our products are priced at least 40% lower than imported machines, and we offer swift support services, ensuring quick accessibility for our customers. We have also established agreements to supply high-technology machines to the government and are committed to collaborating with them to develop new powders and components. This presents a significant opportunity for amace, as we strive to make 3D printing accessible and affordable for Indian customers.

Many believe that 3D printing is prohibitively expensive, but our turning and milling machines have successfully transformed manufacturing before. Our goal is to replicate this success with 3D printing. In the next three to five years, we anticipate seeing the results of our collaboration with the government. This is a monumental step forward for amace, akin to reaching the moon. Ultimately, our customers and Indian users will benefit, leading to lower component costs and potentially making air and space travel more affordable.

Ace Designers is deeply invested in skilling the next generation and equipping them with the right expertise. T.K. Ramesh, Managing Director, Ace Designers Ltd., shares that the group has dedicated machines, simulators, and a focused team to strengthen the education and training section.

How is the machine tool industry evolving beyond its traditional connection with the automotive sector?

Machine tools are closely linked to the automotive industry, which continues to play a significant role in the machine tool sector. However, an increasing amount of electronic manufacturing is coming into focus. Automation machines are now being utilised to produce alloy wheels applicable to electric vehicles (EVs) and conventional automobiles.

Additionally, 3D printing technology is an exciting advancement on the horizon. We are exploring applications for parts and machines in aerospace, particularly for new space missions. We are actively involved in several emerging industries, including aeronautics, space, medical, and electronics.

How is the rise of electric vehicles (EVs) impacting the automotive industry, and what role does the machine tool sector play in both traditional and evolving segments?

The rise of EVs has marked a significant shift in the automotive industry, marking a major change in this evolution. EVs have undoubtedly disrupted the automotive sector, particularly in specific areas. However, some segments remain traditional; while they may not rely solely on diesel or petrol, there is still considerable discussion around hybrids. Overall, the automotive industry continues to grow, with machine tools essential in this development.

Another important aspect is the automotive components sector, which has a substantial presence in the industry. Despite the increasing focus on EVs, they still constitute a relatively small portion of the overall market, and the traditional automotive sector remains vital to the machine tool industry. The automotive components industry in India represents a significant business, with billions of dollars generated through auto component exports, largely supported by the Indian machine tool industry.

What strategies is Ace Group implementing to expand its export business?

Exports are a significant focus for us, and we are paying great attention to this area. We are exploring new markets and have established Ace Micromatic International, our export arm. We currently have offices in Mexico, the Middle East, Germany, and China, and we are collaborating closely with partners in the United States.

Exports account for approximately 7 to 8% of our total turnover, and we aim to increase this figure to 15% within the next three years. Our strategy revolves around investing in the export market; we are making investments, setting up offices, and actively engaging with and acquiring channel partners. By 2030, we aim to achieve at least 25% of our sales from export partners.

We are also committed to training and nurturing fresh engineers and operators and collaborating with academia and the broader ecosystem. These efforts will reduce our machines’ total cost of ownership.

How is Ace Group contributing to skill development in the manufacturing sector, and what initiatives are in place to train engineers, operators, and industry professionals?

We have a dedicated arm for skill development, focusing on machines for the education sector and simulators for the education system. Skilling has always been, and continues to be, a significant focus for us. To support this initiative, we have a sales and service network with 50 offices and 70 touchpoints throughout India, which are increasingly equipped to meet customer needs.

Our efforts encompass training fresh engineers and operators, collaborating with academia, and engaging with the entire ecosystem to improve our machines’ total cost of ownership. We are expanding our reach and taking a more proactive role with our customers by supporting them through leasing options and financial partner training.

Additionally, we have launched new books and an entire website to connect with customers, providing access to extensive knowledge that we aim to enhance and enrich. To further strengthen our initiatives, we have machines equipped with various training and teaching aids available to our customers.

Ultimately, there is a strong demand for skilled operators, setters, line managers, and shop supervisors, especially in the small and medium-sized enterprise (SME) and micro, small, and medium enterprises (MSME) sectors. Recognising this need, we are investing in skilling initiatives and have a dedicated team focused on this area.

What role does a strong machine tool base play in the growth of India’s manufacturing sector?

In India, manufacturing growth is closely tied to having a strong machine tool base. The future looks promising in this area. However, there are several initiatives we need to focus on, such as improving productivity and managing costs. The cycle is coming full circle—after Europe, Japan, Korea, Taiwan, and, of course, China, it is now India’s turn. While the path forward will not be easy, I am optimistic about the potential of the machine tool industry, especially given the government’s and industry’s collective efforts towards its development.