Agnikul’s New 3D Printing Facility Promises Faster, Smarter Rocket Manufacturing in India

In a landmark moment for India’s private space sector, Chennai-based spacetech startup Agnikul Cosmos has commissioned the country’s first large-format 3D printing facility dedicated to aerospace and rocket systems, reported Times of India today. Located at the IIT Madras Research Park, the facility integrates design, simulation, printing, post-processing, and testing under one roof—dramatically accelerating the production of flight-ready hardware.

image Credits – News IADN@X

“This is not just a milestone for Agnikul, it is a statement of national capability,” said Moin SPM, Co-founder & COO of Agnikul Cosmos.

Key Highlights 

• Scale & Capability: First in India to enable 3D printing of aerospace components up to 1 metre in height, previously considered too complex for additive manufacturing.
• Speed & Efficiency: Fully finished rocket engines can now be produced in just days, cutting development cycles and costs by up to 50%.
• Indigenous Innovation: Includes a homegrown de-powdering machine for flawless post-processing, ensuring space-grade quality without external dependencies.
• Patent Power: Agnikul holds a US patent for single-piece 3D-printed rocket engines. The new facility allows production of engines with seven times the thrust of earlier designs.
• Strategic Vision: The facility strengthens India’s space manufacturing ecosystem, positioning it as globally competitive in terms of quality, speed, and affordability.

Founded in 2017 and incubated at IIT Madras, Agnikul previously made headlines by launching its Agnibaan rocket from Sriharikota’s first private launchpad, Dhanush. The startup has raised $45 million to date from investors including Celesta Capital, Rocketship.vc, and Pi Ventures.

Agnikul was started with the goal of making space available to everyone, said Srinath Ravichandran, Co-founder & CEO. “By developing not just printing capacity but also full-scale machines in-house, we are equipping ourselves to build space transportation systems faster.”

With over 250 space-tech startups now active in India, Agnikul’s new facility marks a pivotal step toward a self-sustaining, innovation-driven space economy.

ISRO Successfully Tests 3D Printed Rocket Engine, Made by Wipro's 3D Printing Biz Unit

The Indian Space Research Organisation (ISRO) has achieved a significant milestone with the successful hot testing of a liquid rocket engine manufactured using 3D printing technology. This test represents a major breakthrough in rocket manufacturing.

The test was successfully conducted for a duration of 665 seconds on May 9, 2024, at the ISRO Propulsion Complex in Mahendragiri, Tamil Nadu. The engine tested is the PS4 engine, which is used in the upper stage of ISRO's Polar Satellite Launch Vehicle (PSLV).

The engine is a Made-in-India product, developed by ISRO's Liquid Propulsion Systems Centre (LPSC) and manufactured by WIPRO 3D, a 3D printing and additive manufacturing business of Wipro Limited. Started in 2012, Wipro 3D is a part of Wipro's strategic initiative for the future of manufacturing. Since its inception, Wipro 3D has quickly grown into a leading provider of metal Additive Manufacturing Solutions and Services to the Aerospace, Space, Defense, Industrial & Tooling, Heavy Engineering, Healthcare, Automotive, and Nuclear sectors.

The engine was manufactured using a technique called Laser Powder Bed Fusion, which reduced the number of parts from 14 to a single piece and eliminated 19 weld joints. This new manufacturing process saves 97% of raw materials and reduces production time by 60%.

 

3d printed PS4 engine

The engine uses a bipropellant combination of Nitrogen Tetroxide as the oxidizer and Mono Methyl Hydrazine as fuel. This advancement not only enhances the efficiency of rocket production but also demonstrates ISRO's commitment to innovation and self-reliance in space technology.

The same engine is also used in the Reaction Control System (RCS) of the first stage (PS1) of PSLV. The engine was developed by the Liquid Propulsion Systems Centre (LPSC), ISRO.

LPSC redesigned the engine making it amenable to the Design for Additive Manufacturing (DfAM) concept thereby gaining considerable advantages. The Laser Powder Bed Fusion technique employed has brought down the number of parts from 14 to a single-piece, and eliminated 19 weld joints, saving significantly on the raw material usage per engine (13.7 kg of metal powder compared to the 565 kg of forgings and sheets for conventional manufacturing process) and reduced 60% in the overall production time.

It is planned to induct this AM PS4 engine into the regular PSLV program of ISRO. 

World's 1st 3D Printed Place of Worship Being Built in Telangana

Apsuja Infratech and Simpliforge Creations collaborate to build this one-of-its-kind architectural innovation positioning India as a global pioneer in 3D printed architecture.

Apsuja Infratech, a Hyderabad-based leading construction company has joined forces with Simpliforge Creations, an innovative 3D printed Construction Company, to achieve a remarkable feat in architectural innovation - the creation of the world's first 3D printed place of worship. The 3D printed temple resonates the pride of Telangana as it set to embark an architectural revolution in the nation.

Situated within Charvitha Meadows, at Burugupally, Siddipet, Telangana the 3D printed temple serves as a testament to the harmonious integration of technology and nature with sustainability.

With this radical achievement, Apsuja Infratech and Simpliforge Creations have not only carved a niche for themselves in the construction industry but have also positioned India as a global pioneer in 3D printed architecture.

The groundbreaking three-part structure marvel, a Hindu temple, sprawling over an impressive 3,800 sq.ft, standing tall at about 30 feet is a unique architectural wonder, a one-of-its-kind innovation being built in Telangana. The three sanctums, or Garbhas within the structure represent a 'Modak' (a fig shaped delicacy) dedicated to Lord Ganesha, a Shivalay, a square abode devoted to Lord Shankar, and a Lotus shaped home for Goddess Parvati. The Structure is 3D printed by Simpliforge with their in-house developed system and indigenously developed material and software. This by far is the first 3D printed structure globally as a place of worship at this massive scale.

This landmark achievement not only showcases the immense potential of 3D printed construction but also demonstrates the architectural freedom and capabilities of the robotic arm system developed by Simpliforge team. “Completely printed on-site, the temple's striking dome-shaped structures including the Modak and the Lotus, presented formidable challenges that required the team to employ bespoke design techniques, meticulous analysis, and innovative construction methods, all the while following the principles of Temple architecture resulting in this awe-inspiring architectural marvel.” Said Mr. Hari Krishna Jeedipalli, MD, Apsuja Infratech.

“With the Shivalay and the Modak construction completed, phase II comprising of the Lotus and the tall spires (Gopurams) are already underway.” added Mr. Hari.

Simpliforge Creations, a leading turnkey solutions provider in 3D printed construction, has hailed this project as a testament to the possibilities within the industry. “This structure demonstrates Simpliforge’s ability to print 51º and 32º in outward and inward cantilever, respectively, especially while printing in-situ catering to the architectural/aesthetic requirements. This construction takes care of the structural requirements, principles of temple design, 3d printing requirements, while dealing with the challenges of in-situ construction. This proof of concept also sets the stage for future applications of Simpliforge's robust systems in inaccessible areas like frontiers, high altitude areas, desserts and snowy regions with applications in challenging terrain, disaster hit areas and defence applications.” Said Mr. Dhruv Gandhi, CEO, Simpliforge Creations. “The enclosed dome shaped structures eliminating the need for flat slab roofs paves the way for extra-terrestrial applications which is Simpliforge’s grander vision.”

The world's first 3D printed place of worship stands as an awe-inspiring testament to the harmonious union of human creativity, technological prowess, and architectural finesse. Having also delivered India’s first 3D printed bridge prototype at Charvitha Meadows previously, the 3D printed temple now adds a Global First to the crown of feats at this project.

India’s 1st Prototype Bridge Using Indigenous 3D Printing Technology Developed By Simpliforge Creations and IIT Hyderabad

• A prototype of India’s first 3D Printed Bridge was developed and is being load tested.
• Material and printing technology developed by Simpliforge Creations, a startup company in collaboration with IIT Hyderabad.
• The bridge designed by IIT Hyderabad presents an efficient structural form that was optimized for strength and performance.
• Technology demonstration for 3D printing technology for form-efficient structures in transportation sector.

A prototype 3D printed bridge has been developed and printed as a collaboration between IIT Hyderabad and Simpliforge Creations. The concept and design were developed and evaluated by Prof. K.V.L. Subramaniam and his research group, Department of Civil Engineering, IIT Hyderabad.

The bridge was printed by Simpliforge, a startup company specializing in providing 3D concrete printing solutions. Designed as a pedestrian bridge, the prototype bridge is undergoing load testing and evaluation for functional use. The bridge has been designed at IIT Hyderabad broadly following form optimization to minimize the use of concrete and reinforcement.

The concept of the bridge was developed following the concept of ‘Material follows Force’. Simpliforge Creations developed an extrusion and software system specifically for the project to fully exhibit the merits of their 3D printing system.

Using the Industrial robotic arm 3d printer, the bridge was printed off-site in little under 2 hours at Simpliforge Printing facility and assembled on site at Charvitha Meadows, Siddipet.

 

Enlisting the uniqueness of the 3D Printing technology, Prof K.V.L. Subramaniam, IITH, said, “3D concrete printing is an emerging technology has the potential for transforming the construction industry with the promise of rapid, efficient, and free-form construction. Technology application in this space requires advancements in design methodologies, material processing, and delivery systems.”

“We are proud to have been a part of this ground-breaking project” said Mr. Hari Krishna Jeedipalli, Managing Director, Simpliforge Creations. “This bridge is a testament to the capabilities of 3D construction printing technology and its potential applications in infrastructural requirements, defense, and disaster scenarios owing to its speed and ease. We hope that this project will inspire others to explore the possibilities of 3D concrete printing in infrastructure and other industries.”

Simpliforge is a holistic additive manufacturing Solutions Company with capabilities for Technology Development, System Integration and Service Solutions. Simpliforge provides complete prototyping and manufacturing solutions for products spanning the FMCG sector to niche domains. For Construction Industry, Simpliforge provides Technology & Materials Development, Equipment manufacturing & Integration and End-to-end construction solutions. Powered by manufacturing domain experts, localized production facilities and international design experts, Simpliforge delivers services in the afore mentioned domains.

First of its Kind 3D Printing Facility Opens at Bengaluru Airport City

Peekay Group’s State-of-the-art 3D Printing Facility opens at Bengaluru Airport City

This is the first-of-its-kind facility in India with a focus on engineering, design and collaboration. 

A state-of-the-art 3D printing facility is now operational at the Airport City that is being developed in the BLR Airport premises. The Peekay Group in partnership with Bengaluru Airport City Limited (BACL) inaugurated this first-of-its-kind facility, that focuses on engineering, design and collaboration.

"We are excited to inaugurate this state-of-the-art 3D printing facility at our Airport City and partner with the Peekay Group. This facility will act as a catalyst to help transform our Airport City into a technology hub. From healthcare to sustainable construction and aerospace, 3D printing helps develop a culture of creativity and scope for scaling innovation across industries. This technology will further help consolidate Bengaluru’s strategic position as a knowledge-based economy, and as the Silicon Valley of India. A technology hub coupled with upcoming world-class retail, dining, and entertainment facilities will make our Airport City a truly global destination,” says Rao Munukutla, CEO, BACL.

The facility houses a production centre and an experience zone that will train individuals and students in 3D printing. It will also be an incubation centre for those who want to ideate innovative solutions. One of the aims of this new set-up is to increase awareness about 3D printing applications and to train technology experts who want to upgrade their skills.

“With our vast experience and the trust for quality, delivery and cost which we have built over the last few decades, we are confident that Peekay can contribute immensely towards skill development, design-based thinking, and optimisation of products for customer benefit. Over and above this, we intend to tie up with world-renowned universities to embark on various training programs and symposiums to nurture the enthusiasm and creativity in today’s youth by utilising design-based reasoning as a foundation to synchronise all manufacturing processes,” says K.E. Shanavaz, Joint Managing Director, Peekay Group.

Additive Manufacturing popularly known as 3D Printing is used widely in industries like architecture, construction, automotive, aerospace, military, biotech (human tissue replacement) jewellery designing, education, and other fields. Going forward, the Peekay Group plans to install a 3D metal printing unit to cater to the niche demand from the aerospace industry. “With the various additive manufacturing processes, we are planning to add to this facility, we believe we can create a considerable number of high-quality jobs in the aerospace industry in the future. Furthermore, the social impact will be notable with the adoption of ‘The Go Green’ concept which will spearhead the reduction of our carbon footprint,” adds Shanavaz.

The global 3D printing market size is estimated to reach US$ 62.79 billion by 2028 and is expected to witness a CAGR of 21.0% from 2021 to 2028. McKinsey predicts that Additive Manufacturing could have an economic impact of $550 billion annually by 2025.

Traditional manufacturing impacts the environment negatively, however, 3D printing is an eco-friendly technology that reduces carbon footprint significantly. The giant 3D sand printing machine that is installed at Airport City is the first of its kind globally. It is the most efficient and environmental-friendly machine with no carbon emission-- in line with Bangalore International Airport Limited’s sustainability framework. The Airport City is developed as an international gateway to a Sustainable, Smart, Vibrant city celebrating a culture of innovation. The collaboration between BACL and Peekay is a significant milestone for future endeavours in this space.

“We are actively making our Airport City truly smart. Our smart streetlight system is the first of its kind in an airport ecosystem in India. We have been awarded the ‘Most Innovative Best Practice for Project Digitalisation of Infrastructure Development in Bengaluru Airport City’ by the Confederation of Indian Industries (CII),” added Rao Munukutla.

About Bengaluru Airport City Limited

Bengaluru Airport City Limited (BACL), incorporated on January 21, 2020, is a wholly owned subsidiary of Bangalore International Airport Limited, BIAL (operator of Kempegowda International Airport, Bengaluru).

BACL has been founded to develop the Airport City at BLR Airport as a world-class destination of a truly mixed-use development, consisting of Business Parks, Health District, Retail Dining & Entertainment Village, Concert Arena, Convention & Exhibition Centre, Knowledge Park, Hospitality & Central Park. The Airport City is developed as an international gateway to a Sustainable, Smart, Vibrant city celebrating a culture of innovation.

The Airport City will embrace Innovation 24x7 and will be the test bed for global urban solutions. This futuristic Airport City is being developed applying core principles of Work, Play, Live, Learn & Create which shall leverage airport accessibility for commercial development and economic growth. BACL is committed to establishing the Airport City as one of India’s leading projects in terms of quality and efficiency and setting a benchmark for future commercial developments in India.

About Peekay Group

Peekay Group is a leading industrial group from Kerala. They are one of the emerging players in South India, with manufacturing locations spread across four states. Over a decade, Peekay has expanded and diversified its activities consistently to remain a market leader in all the areas it operates in. Today Peekay Group’s activities cover different verticals ranging from engineering, metal, food, education, and healthcare. The total turnover of the group is over Rs. 1000 crores per annum.

Peekay Steel Castings Pvt. Ltd. is a flagship company of Peekay Group which produces industrial components and exports to over 32 countries today from its various manufacturing locations in India viz Calicut (Kerala), Coimbatore (Tamil Nadu), and Hindupur (Andhra Pradesh). The company caters to several global OEMs such as General Electric, Schlumberger, Komatsu, Wabtec, Baker Hughes, Siemens, Man Turbo, Emerson, and many others in The Fortune Global 500 list. Today, Peekay Steel is rated as one of the five best steel casting manufacturers globally, catering to oil & gas, power, mining, transportation, and other engineering sectors.