Abilities India Pistons & Rings Ltd., a name in the manufacturing of Pistons, Piston Rings, Gravity Casting, Pressure Die Casting, and Coatings, has announced the grant of its SECOND patent for its High-Pressure Die Casting (HPDC) process for lightweight piston manufacturing. This breakthrough is expected to reduce the weight of 2W/3W pistons by 10-15%, resulting in a substantial annual aluminium saving of 307.5 tons based on the current annual output of 20 million 2W/3W vehicles. By 2030, this saving is projected to increase to 461.25 tons annually. Corresponding carbon emission reduction will be 920 tons /annum presently & 1380 tons/annum by 2030 respectively Abilities India’s immediate priorities include leveraging these patented technologies domestically and internationally, alongside the development of critical components to support the self-reliance goals of leading Indian OEMs.
Furthermore, the company achieved a noteworthy revenue of INR 128 Cr in FY24 & is poised for substantial growth in the years ahead fuelled by technological advancements. It is on course to achieve a top line of INR 225 crores approx. in FY 2026 & increase in EBIDTA from 14% in FY 2024 to 16% approx. in FY 2026. To bolster this trajectory, the company intends to double the size of its R&D team and increase fund allocation to 3% of revenue. Currently, its manufacturing facility spans 5 acres in a single location with a built-up area of 14,153 square meters. Plans are underway to expand by an additional 3000 square meters in FY25/26, with an investment of INR 20 crores, supplementing the INR 17 crores invested in FY24.
Traditionally, pistons for gasoline and diesel engines are produced using the Gravity Die Casting (GDC) process, optimized for mass production but constrained by thicker wall thicknesses and higher machining allowances. However, AIP’s High-Pressure Die Casting (HPDC) process revolutionises piston manufacturing. By subjecting the molten metal to high pressure within a mould, it achieves intricate contours and desired geometry, resulting in pistons with minimal machining requirements. This innovation, applied to various piston types, signifies a significant leap in engine component technology, addressing stringent emission regulations for both 2-stroke and 4-stroke engines. The process addresses the evolving needs of the automotive industry of tightening emission standards and the demand for lightweight, high-performance components.
Sunil Arora, Chairman and MD, Abilities India Pistons & Rings Ltd. said, “At Abilities India, we are dedicated to pioneering research and technological advancements within the auto components industry. Our second patent underscores our unwavering commitment to innovation and sustainability in automotive manufacturing. With the development of this cutting-edge manufacturing process, we are improving engine performance and actively reducing emissions, thus shaping the future of automotive technology. This milestone reinforces our position as leaders in sustainable and efficient solutions for the global mobility domain.”
Tushar Arora, Jt. MD & CEO, Abilities India Pistons & Rings Ltd. commented, “Our newly patented High-Pressure die-casting process is a game-changer for the automotive industry. By reducing piston weight, we are enhancing fuel efficiency and engine performance while also cutting down on material usage and carbon emissions. We are excited about the transformative potential of this technology.”
Abilities India remains dedicated to research and development, continually exploring avenues to enhance coating properties and broaden applications, ensuring continuous innovation and meeting the growing demand for advanced automotive components.