Major Trends Influencing Demand for Custom Steel Castings in India

Indranil Dutta, CEO of Datre Corporation in an interaction with Industry Outlook, shares insights on how India’s growing industrial focus is boosting demand for custom steel castings across infrastructure, automotive, exports, and high-performance sectors. He highlights the role of 3D printing and strategic collaborations in enabling precision, faster prototyping, and cost efficiency, while also emphasizing the shift toward sustainable and hybrid manufacturing practices to meet rising customization needs.

What are the major industry and market trends contributing to the rising demand for custom steel castings in India across infrastructure, automotive, exports, and high-performance applications?

India’s evolving industrial landscape and global positioning are fueling new avenues for custom steel castings across multiple sectors.

Infrastructure Development: India’s focus on large-scale infrastructure projects, such as metro railways, DFD and passenger trains initiatives through the Gati Shakti Master Plan, is significantly increasing the demand for steel castings. These projects require durable, high-strength components for construction equipment, railways, and mining equipment. Urbanization and real estate growth are driving demand for steel castings in construction machinery, structural components, and fittings. For instance, construction spending in India breached USD 2 trillion in 2024, fueling demand for cast components.

Growth in the Automotive Sector: The automotive industry, particularly the shift toward lightweight and fuel-efficient vehicles, is a major driver. The demand for precision-engineered steel and alloy castings for components like transmission cases, engine parts, and chassis is rising due to increased vehicle production (26.36 million vehicles manufactured in India in 2020). The rise of electric vehicles (EVs) and hybrid vehicles is creating new demand for specialized castings, such as battery housings and motor components, as manufacturers adapt to stricter emission regulations and consumer interest in sustainable transportation.

Global Market Expansion and Export Growth: Indian steel casting manufacturers are increasingly exporting to Europe, North America, and Asia, driven by competitive pricing and high-quality products. India’s strategic geographic location and skilled labor force at lower costs make it a preferred hub for global clients. The “Make in India” initiative is encouraging local manufacturing and innovation, boosting the global competitiveness of Indian foundries.

Demand for Specialized Alloys and High-Performance Castings: Industries like aerospace, defense, and renewable energy are driving demand for specialized steel alloys that offer high strength, corrosion resistance, and heat resistance. For example, cast components are critical in wind turbine systems and aerospace engine parts. The renewable energy sector, particularly wind and solar, is an emerging growth area, with castings used in hubs, frames, and generator casings.

What are the emerging industries or sectors that could benefit most from custom steel castings, and how can manufacturers tailor their offerings to meet these demands?

Renewable Energy (Wind and Solar): India’s renewable energy sector is expanding rapidly, with a target of 500 GW of non-fossil fuel capacity by 2030. Wind turbines and solar infrastructure require robust, corrosion-resistant castings for components like hubs, rotor shafts, frames, and generator casings. High-strength steel and alloy castings that withstand extreme weather and mechanical stress are essential. For wind turbines, large-scale castings (e.g., 3–5 tons for hubs) with precise tolerances are critical. The renewable energy sector’s growth is supported by government initiatives like the National Solar Mission, driving demand for castings as wind and solar installations increase.

Electric Vehicles (EVs) and Hybrid Vehicles

India’s EV market is projected to grow at a CAGR of 49% from 2022 to 2030, driven by policies like FAME II and consumer demand for sustainable transport. EVs require lightweight, durable castings for battery housings, motor components, and chassis, including lightweight steel or alloy castings (e.g., aluminum-steel hybrids) to improve energy efficiency, along with precision castings for complex geometries in electric motors and transmission systems.

Aerospace and Defense

India’s aerospace sector is growing due to initiatives like “Make in India” and increased defense spending (USD 81 billion defense budget in 2024). Aircraft and defense systems require high-performance castings for engine parts, landing gear, and structural components, including heat-resistant, corrosion-resistant, and lightweight alloy castings (e.g., nickel-based or titanium alloys) that meet stringent safety and performance standards like AS9100. Collaborations with global players like Boeing and domestic programs like the Tejas fighter jet are creating opportunities for precision castings.

Railways and High-Speed Rail

Projects like the Mumbai-Ahmedabad Bullet Train and metro rail expansions in cities like Delhi and Bengaluru are increasing demand for castings in rail infrastructure, bogies, and rolling stock components. High-strength, fatigue-resistant steel castings for bogie frames, couplers, and wheelsets ensure safety and durability under high-speed conditions. The Indian Railways’ modernization plan, with investments of INR 2.4 trillion by 2024, underscores the growing need for custom castings.

Green Hydrogen and Energy Storage

India’s National Green Hydrogen Mission aims to produce 5 million metric tons of green hydrogen annually by 2030, and this sector requires castings for electrolyzers, storage tanks, and turbine components. Therefore, corrosion-resistant, high-pressure-resistant steel castings capable of handling hydrogen’s unique properties are essential to ensure safety in storage systems.

How can advancements such as 3D printing technology enhance the precision and efficiency of custom steel castings for specialized machinery?

Advancements like 3D printing (additive manufacturing) are revolutionizing custom steel casting production in India, particularly for specialized machinery. By enhancing precision, efficiency, and flexibility, 3D printing is crucial for industries such as aerospace, automotive, renewable energy, and defense, which require complex, high-performance components. It enables the production of intricate molds, patterns, and metal parts that traditional methods can’t easily achieve—ideal for turbine blades, impellers, and EV motor housings. The technology ensures high dimensional accuracy (±0.1 mm) and smooth finishes, reducing post-processing.

3D-printed sand molds help minimize casting defects like shrinkage or porosity. The technology also shortens prototyping cycles from weeks to days, speeding up development—especially in sectors like railways. Manufacturers can use 3D-printed wax or resin patterns for quick iterations of components like railway bogies. Additive manufacturing reduces material waste by 30–40% and lowers energy use, making it ideal for high-value alloys and aligned with India’s sustainability goals.

Additionally, 3D printing allows the creation of complex internal structures in molds without manual assembly. Binder jetting technology enables mold production directly from digital designs, cutting lead times by up to 50% and ensuring consistent quality. Integrated with CAD, simulation, and digital twin tools, it helps optimize designs and reduce defects, ensuring custom castings meet exact specifications.

In what ways can the custom steel casting industry adopt sustainable practices, such as the use of recycled materials, without compromising on quality and performance?

The custom steel casting industry in India can adopt sustainable practices, including the use of recycled materials, to reduce environmental impact while maintaining quality and performance. This is critical given India’s push for sustainability, driven by net-zero goals, regulatory pressures, and growing demand for green steel in sectors like automotive, renewable energy, and infrastructure. Below, I outline key sustainable practices, focusing on recycled materials.

For instance, incorporate high-quality steel scrap and recycled alloys as primary raw materials in casting processes, particularly in electric arc furnaces (EAFs) or induction furnaces. India generates significant steel scrap which can be sourced domestically or imported. Additionally, adopt energy-efficient technologies like EAFs, induction furnaces, and waste heat recovery systems to minimize energy consumption. Recycle used foundry sand for mold and core production, using thermal or mechanical reclamation processes.

Advanced systems can recover up to 90% of sand, reducing the need for virgin silica sand. Sand recycling minimizes mining, reduces waste disposal. Moreover, convert foundry byproducts like slag into usable materials, such as cement additives or road construction aggregates. Implement closed-loop water recycling systems to minimize water waste. Finally, use 3D printing to create precise molds and patterns, reducing material waste in mold-making. Direct metal printing for small-batch castings further minimizes excess material use.

How can manufacturers balance the cost-effectiveness of standardized steel components with the growing demand for highly customized parts in specialized machinery?

Balancing the cost-effectiveness of standardized steel components with the growing demand for highly customized parts in specialized machinery is a critical challenge for Indian manufacturers, particularly in industries like aerospace, electric vehicles (EVs), renewable energy, and railways. The key is to optimize production processes, leverage technology, and adopt hybrid strategies that cater to both standardized and customized demands without compromising quality or profitability. For example, use modular molds or patterns for castings that serve as a common base for components like EV motor housings or railway bogie frames, with customizable features. This reduces tooling costs and inventory complexity, while meeting client-specific requirements. Use 3D printing to produce customized molds, patterns, or small-batch components, while relying on traditional casting for high-volume standardized parts. This hybrid approach minimizes the cost of custom tooling.

Additionally, invest in binder jetting systems for 3D-printed sand molds to create complex, client-specific castings for aerospace, while using conventional sand casting for standard parts like construction machinery components. Equip foundries with CNC machining centers and IoT-enabled furnaces that adjust parameters (e.g., alloy composition, pouring temperature) for different casting types. This is particularly effective for sectors like EVs and railways, where both standard and custom parts are needed. Use just-in-time (JIT) production and demand forecasting to balance inventory of standardized components with on-demand production of customized parts. This reduces storage costs while ensuring timely delivery of custom orders.

What role do collaborations between steel casting companies and machinery manufacturers play in driving innovation and expanding opportunities in this niche market?

Collaborations between steel casting companies and machinery manufacturers in India are crucial for driving innovation and growth in the custom steel casting market, especially for specialized machinery in sectors like EVs, renewable energy, aerospace, railways, and defense. These partnerships enable co-development, improve quality, reduce costs, and unlock new market opportunities, leveraging India’s cost efficiency, skilled labor, and supportive policies like “Make in India.”

Steel casting companies work closely with machinery manufacturers to co-design components that meet specific performance, weight, and durability needs. Joint R&D helps develop new alloys, casting techniques, and optimized geometries for applications like lightweight EV battery housings, corrosion-resistant wind turbine hubs, or high-strength aerospace parts. Collaborative design reduces trial-and-error and ensures components meet strict standards.

These partnerships also enable rapid prototyping and validation through real-world performance data and testing facilities, accelerating product development. Long-term supply agreements provide casting companies with stable demand and reduce market risks. Resource sharing—such as R&D labs, testing centers, and supply chains—lowers costs and enhances efficiency. Machinery manufacturers offer insights into end-use requirements, allowing for better-optimized and more cost-effective casting designs.