The global automotive industry is in a relentless race to shed weight, driven by stringent emissions regulations, safety standards, and the burgeoning demand for electric vehicles. While aluminum and novel composites frequently grab headlines as lightweighting solutions, Sachin Bhoutkar, Director, R&D, BIW India at Gestamp, a leading global supplier of metal components for the automotive industry, argues that advanced steel technologies—particularly hot stamping—offer a compelling and often more cost-effective path forward for the Indian market.
His insights underscore a strategic pivot toward high-strength steel solutions and a call for deeper, earlier collaboration between suppliers and original equipment manufacturers (OEMs). Bhoutkar spoke during a panel discussion at a virtual vehicle lightweighting conference organized by Autocar Professional on June 12–13.
Forging Strength, Cutting Weight
Gestamp is no stranger to the complexities of material formability, having honed its expertise over nearly 25 years, especially with hot stamping materials. This includes sophisticated roll-forming simulations using tools like Copra and LS-Dyna, leveraging significant in-house knowledge to tackle challenges.
Bhoutkar highlighted that hot stamping technology allows for the use of materials with significantly increased strength, reaching up to 1500 MPa. This elevated strength enables fundamental design changes, leading to considerable reductions in vehicle weight, fewer individual parts, and thinner gauges.
For instance, Gestamp globally employs martensitic steels with an ultimate tensile strength (UTS) of 1500 MPa for components such as rockers and seat crossmembers. Despite this advanced capability, he noted that raw material variations can cause discrepancies between simulated formability results and real-world try-out outcomes.
Moreover, while the material is flexible, springback (the elastic recovery of material after it is physically deformed) remains a significant concern, especially when dealing with very low material thicknesses.
The Collaboration Imperative
A recurring theme in Bhoutkar’s discussion was the absolute necessity of early and in-depth co-design and co-development with customers. He stressed that such collaboration is “very critical” because some OEMs may not be fully acquainted with the capabilities and limitations of these advanced technologies.
“The concept defines how you are going to meet the cost,” he stated, emphasizing that early engagement with customers to define and validate the design concept on the full vehicle is crucial for managing costs effectively. While Gestamp is ready to bring advanced high-strength steel (AHSS) and ultra-high-strength steel (UHSS) technologies, he noted that it only becomes “a very viable business case” if OEMs design vehicles with the availability of such technology in mind.
Cost-Cutting Through Consolidation
In a market perpetually sensitive to costs, Bhoutkar asserted that Gestamp’s solutions—particularly those leveraging hot stamping—are quite cost-competitive. He specifically addressed the Indian market’s unique cost landscape, noting that aluminum is another big cost-negative topic. As a strategic counterpoint, Gestamp is pioneering giga stamping solutions.
He offered a compelling example of a “door ring,” where four distinct parts—the B-pillar, sill, hinge pillar, and end—are integrated and stamped as a single component. This innovation not only reduces overall weight and simplifies the management of multiple suppliers but also allows for reduced gauge and enhances the product’s safety and integrity, all while remaining cost-competitive.
He positioned these giga stamping solutions as a strong counter to giga casting, implying a strategic alternative to other emerging manufacturing trends.
Way Forward
Bhoutkar suggests a future where advanced steel solutions, supported by deep supplier-OEM collaboration and innovative manufacturing processes like giga stamping, will play a central role in achieving lightweighting and cost efficiency in the Indian automotive sector. This strategic focus on high-strength steel offers a robust pathway for manufacturers navigating the complex interplay of regulatory demands, material costs, and evolving vehicle architectures.