Optimising vehicle dynamics through advanced aerodynamics, torque vectoring, and camber control systems is proving vital in reducing energy consumption and enhancing overall efficiency.
With the global push for sustainability gaining momentum, the automotive industry finds itself at the heart of transformative change. From cleaner fuels to smarter materials, the shift to sustainable mobility is being shaped by a confluence of global goals, innovative technologies, and evolving regulations.
The United Nations’ 17 Sustainable Development Goals underscore the urgency for environmentally responsible practices, Dr N Karuppaiah, Senior Project Advisor, CAAR, has said. Speaking at the SAE India Automotive Leadership Summit organised alongside Automotive Testing Expo 2025, he said, for automotive sector, this translates into accelerated adoption of EVs, alternate fuels, and a sweeping embrace of the circular economy—anchored in the principles of reduce, reuse, recycle, and recover.
A Multi-Fuel Future
The industry’s transition is well underway with a growing footprint of battery electric vehicles (BEVs), hydrogen fuel cell vehicles, and hybrids. Alternate fuels—biogas, CNG, LPG—also play a critical role in reducing dependency on fossil fuels. Meanwhile, EVs continue to drive innovation with improvements in battery density, charging speed, and life cycle efficiency.
The rise of circular practices sees increased use of biodegradable materials, recycling of batteries, and repurposing of vehicle components. End-of-life policies like India’s scrappage scheme further support the ecosystem, encouraging responsible recycling and reuse.
Lightweighting, Design Innovation
Reducing vehicle weight is crucial to improving fuel efficiency and extending EV range. A 10% weight reduction can result in a 6–8% drop in fuel consumption, he said. Industry leaders are turning to lightweight materials such as high-strength steel, aluminium, composites, carbon fibre, and even sustainable options like bamboo—used innovatively in interior parts and steering wheels, he pointed out.
Design approaches such as topology optimisation, monocoque and honeycomb structures, and multi-material strategies ensure strength with less material. Centralised ECUs and thinner wiring harnesses through higher-voltage systems are further slashing weight, he observed.
Smart Vehicle Dynamics, Energy Recovery
Sustainability isn’t just about what goes into the vehicle, but also how it moves. Vehicle dynamics optimisation through improved aerodynamics, torque vectoring, and energy-efficient cornering using camber control systems are emerging as key contributors to lower energy consumption.
Four-wheel steering systems paired with torque vectoring can reduce propulsion power consumption by up to 17% during complex manoeuvres, while regenerative braking systems can recover up to 26% of energy otherwise lost, he highlighted.
Regenerative Suspension, Smart Materials
Advanced regenerative suspension systems like electromagnetic, hydraulic, and piezoelectric harvesters are reclaiming energy that was once dissipated as heat. The use of MR damper (Magneto-Rheological – a type of shock absorber that uses a unique fluid called magneto-rheological fluid to control vibrations and oscillations) enables electronically controlled ride comfort while contributing to energy recapture.
Skateboard Platforms, e-Corner Modules
According to Dr Karuppaiah, in EV architecture, the skateboard chassis simplifies production, enhances modularity, and supports localised manufacturing—all aiding sustainability. The e-corner module integrates propulsion, suspension, steering, and braking into a single wheel unit—eliminating the need for traditional linkages and enabling fully independent control, ideal for autonomous vehicle applications.
Efforts to improve EV efficiency continue with initiatives targeting faster battery characterisation—cutting test times from six months to six days—and boosting motor efficiency from the current 60% to as high as 90%, thereby reducing energy use and battery size, he revealed.
Manufacturers are aligning with carbon-neutral goals by adopting smart, sustainable manufacturing practices. Compliance with Environmental, Social, and Governance (ESG) frameworks is becoming integral to operations, ensuring the entire automotive value chain is future-ready.
The Road Ahead
From bamboo to giga casting, from regenerative braking to 3D-printed components, the journey to sustainability is redefining the automotive landscape. As electrification, digitisation, and circularity converge, the road ahead points to an industry not just meeting targets—but shaping a cleaner, smarter future, he concluded.
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