Gestamp, which specialises in the design, development, and production of highly engineered metal components, is spearheading innovation with a sharp focus on safety, light weighting, and sustainability, writes Ashish Bhatia.
Gestamp, a leading global automotive technology company specialising in the design, development, and production of highly engineered metal components, is spearheading innovation with a sharp focus on safety, light weighting, and sustainability. With India emerging as a key market for auto component suppliers, Gestamp’s advancements in large-format stamping, high-strength materials, and eco-conscious manufacturing are reshaping the mobility landscape. The company’s recent showcase at the Bharat Mobility Global Expo unveiled a range of next-generation products designed to meet the evolving needs of internal combustion engine (ICE) vehicles, hybrids, and electric vehicles (EVs) is a testimony.
Crash-Resistant Innovations
Gestamp continues to raise the bar for vehicle safety with its advanced engineering solutions, including the newly introduced GES-GIGASTAMPING® product line, averred Glyn Jones, Country Manager, Gestamp India. This large-format stamping technology combines multiple body parts into a single, high-strength unit, enhancing crash safety by improving the structural integrity of the vehicle’s safety cell. By replacing multiple cold- and hot-stamped parts with a single-piece component, Gestamp is streamlining the assembly process while enhancing vehicle durability and crash performance.
Additionally, Gestamp unveiled its Highpertubes (high-strength tubular) components manufactured using advanced hydroforming technology. These play a vital role in occupant protection during collisions by providing enhanced energy absorption and deformation resistance. Designed for both ICE and EV platforms, Highpertubes offer significant improvements in crash performance while optimising material efficiency and reducing vehicle weight.
In India, where rising road accidents have prompted stricter safety norms, Gestamp’s crash-resistant solutions are particularly relevant. As OEMs strive to meet Bharat NCAP standards, the adoption of Gestamp’s advanced safety products is expected to become increasingly widespread. The company’s focus on safety innovation is helping Indian auto makers develop vehicles that offer greater protection for passengers and pedestrians alike.
Light Weighting Solutions
As the auto industry shifts towards electrification and fuel efficiency, Gestamp’s light weighting technologies are gaining prominence. The company’s GES-GIGASTAMPING® technology not only enhances safety but also reduces vehicle mass by consolidating multiple parts into a single, lighter component. This innovation supports both conventional and electric powertrains, helping OEMs improve fuel efficiency and EV range.
In addition to large-format stamping, Gestamp’s light weighting portfolio includes Active Frunk technology, specifically designed for EVs. The Active Frunk features a fully automatic powered system for opening and closing the front lid while incorporating active pedestrian protection measures. By combining functionality with safety, this innovation offers EV manufacturers a space-efficient and lightweight solution that enhances both convenience and crash protection.
Gestamp’s use of Advanced High-Strength Steel (AHSS) and multi-material combinations further enhances vehicle performance. These materials allow auto makers to reduce overall vehicle weight without compromising crash resistance, contributing to improved fuel economy and reduced CO₂ emissions. As India enforces stricter CAFE norms and prepares for Bharat Stage VII emission regulations, Gestamp’s lightweight solutions are becoming integral to OEMs’ strategies for achieving compliance.
Eco-Conscious Manufacturing
Sustainability is embedded in Gestamp’s DNA, with the company aiming for carbon-neutral production by 2050, emphasised Jones. Its green manufacturing strategies include shifting to 100 per cent renewable electricity by 2030 and incorporating recycled materials into its products. He highlighted the commitment to circular economy practices, including the use of low-emission steel and advanced scrap management systems.
The company’s integrated scrap management ensures full life cycle traceability, from collection and sorting to the reuse of high-quality scrap steel. This promotes the use of recycled materials, reducing the reliance on primary resources and minimising the environmental impact of automotive production. Gestamp’s focus on using secondary raw materials supports auto makers in achieving lower vehicle life cycle emissions, a key priority in the push for sustainable mobility.
Furthermore, Gestamp is advancing low-emission steel solutions through partnerships with steel suppliers, helping OEMs meet increasingly stringent carbon footprint targets. In India, where the government is promoting green manufacturing practices, Gestamp’s eco-conscious initiatives position it as a preferred partner for sustainability-focused auto makers.
Technology-Led Innovation
Gestamp’s Technology and Innovation Office is driving the development of future-ready solutions for a rapidly evolving automotive landscape. The company’s latest product innovations, showcased at the Bharat Mobility Global Expo, reflect its focus on engineering components for multiple powertrains, including ICE, hybrids, and EVs. A key highlight of Gestamp’s innovation pipeline is its Active Frunk for EVs, which combines automated functionality with pedestrian protection. This solution underscores the company’s commitment to developing multi-functional, safety-centric components that address the unique needs of electric mobility.
In addition, Gestamp’s Highpertubes leverage hydroforming technology to produce ultra-high-strength chassis and crash-absorbing structures. These components are designed to reduce vehicle weight while enhancing crash resistance, making them ideal for both conventional and electric vehicles, explained the leadership at Gestamp.
Gestamp’s use of digital twins, advanced simulation, and AI-driven quality control optimises product development and manufacturing efficiency. As India’s auto component sector embraces Industry 4.0, Gestamp’s technology-driven approach strengthens its position as a leader in delivering precision-engineered, high-performance solutions.
India-Focused Roadmap
With manufacturing facilities in Pune, Chennai, and Sanand, Gestamp is well-positioned to cater to the country’s growing demand for advanced auto components. Gestamp’s India-specific road map includes localising the production of its latest innovations, such as GES-GIGASTAMPING® and Highpertubes, to support domestic OEMs in reducing costs and improving supply chain efficiency. By collaborating with auto makers on co-engineering projects, Gestamp is tailoring its solutions to meet India’s unique market requirements, such as rugged terrain durability and cost efficiency. The company is also investing in R&D initiatives focused on developing lightweight, high-strength, and sustainable components for the Indian market. ACI
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