In an exclusive interview, Carborundum Universal Limited (CUMI) shares insights into its pivotal role in India's defence sector. With a 70-year legacy in materials science, CUMI is at the forefront of developing advanced materials that are crucial for modernising India's defence capabilities. From lightweight ceramics for body armour to composites for unmanned aerial vehicles, CUMI's innovations are contributing significantly to the country's self-reliance in defence manufacturing. The company discusses its collaborations with DRDO, strategic partnerships, and its vision for the future of India's defence industry.
Q. The Indian government has emphasised self-reliance in defence. How is CUMI's focus on advanced materials, such as ceramics, composites, and graphene, contributing to this goal? Could you elaborate on how these materials are specifically enhancing the performance of defence systems?
A: The phased import embargo on defence equipment from 2020, coupled with the government’s decision to turn India’s defence sector more self-reliant, afforded a breakthrough for domestic manufacturers like CUMI. The government’s aim is to increasingly source specific equipment and components from domestic companies rather than rely on imports.
CUMI’s focus is on advanced material science which is the base to design cutting-edge products and solutions. This puts us in a position to add significant value in modernising defence with materials for a range of applications such as personal and vehicle armour, composites for Unmanned Aerial Vehicles (UAVs), thermal barrier coatings (TBCs) used in various defence and space applications, and materials for energy storage.
We have been manufacturing and supplying technical-grade ceramic products engineered from Reaction Bonded Silicon Carbide (RBSiC), high purity Alumina, and Zirconia toughened Alumina to leading Original Equipment Manufacturers (OEMs) for bulletproof vests and armoured vehicles. We also supply composites to India’s top drone manufacturer.
Advanced Ceramics – Lighter and more effective protection
RBSiC is the preferred ceramic of choice for wheeled armoured fighting vehicles. CUMI's advanced ceramics, particularly RBSiC, offer a superior alternative to traditional bulletproof vests and vehicle armour made from heavy steel alloys. Not only are they remarkably lighter, but also offer excellent ballistic protection while enabling a more unrestricted range of motion, reducing soldier fatigue. There is significant, fast-growing demand for RBSiC from bulletproof vest manufacturers as India has the second largest number of military personnel in the world. Hence, we are expanding our RBSiC production capacity fivefold.
Composites – Robust but lightweight
Combining materials like carbon fibre and polymers offer exceptional strength-to-weight ratios. This helps design lighter yet sturdier components that can be multi-functional, with application in UAVs and even aircraft structures. Composites show promise in making next-gen defence systems faster, easily manoeuvrable, and highly durable.
Graphene – The ‘wonder’ material
CUMI's ongoing research on Graphene, a revolutionary nanomaterial, studies new ways to leverage its unique properties to develop lighter and stronger airframes for next-gen manned and unmanned aircraft. The potential to equip civil and military aircraft with enhanced protection and even for stealth applications, further underscores the transformative potential of graphene in defence.
CUMI is actively investing in R&D for new-age materials like graphene. This not only reduces dependence on foreign imports but also empowers the nation to develop home-grown world-class defence solutions that meet the evolving needs of Indian defence.
Q. Lightweight yet high-strength materials are crucial for modern defence. How is CUMI leveraging its materials science expertise to innovate in areas like body armour, vehicle protection, and aerospace components?
A: Our persistent R&D efforts in the field of materials science and engineering for the last 70 years has enabled CUMI to revolutionise the world of defence with top-grade materials that adhere to the highest standards of excellence.
CUMI’s highly skilled research experts and technologists have helped create pioneering solutions that offer a high performance-price ratio, extreme toughness, durability, and reliability, and customisability.
Body Armour – Traditional metal armours were bulky and restricted soldier mobility. Our RBSiC, high purity alumina and Zirconia-toughened Alumina product range is exceptionally tough yet lightweight, with a fine-grained microstructure for highest ballistic protection– ideal for bulletproof body and vehicle armour.
Vehicle Protection – Our vehicle armour fabrications offer outstanding protection with the advantages of significant weight reduction for improved manoeuvrability and fuel efficiency. Innovations in customising ceramics such as rubberised ceramics for superior vehicle protection conform to the exact profile do not hinder movement, while being weather-, fire-, and impact-resistant. With materials science expertise, we can also customise tile shapes and configurations to maximise ballistic protection in projectile multi-hit scenarios.
Aerospace Components – We are among the few manufacturers of Yttria-stabilised Zirconia (YSZ) in India, a material critical to produce protective thermal spray coatings and barrier coatings. YSZ TBCs protect critical aero engine components from extreme heat and wear & tear, ensuring efficient operation and extended lifespan for these vital defence systems. Further, our leading research on graphene for UAVs and particularly in stealth will enable key strides in defence strategy.
Q. Our deep expertise in materials science and significant R&D strength enable CUMI to constantly push the boundaries of what’s possible and unearth unique solutions.
CUMI's collaborations with DRDO and other defence partners are well-known. Can you highlight any recent joint projects demonstrating your commitment to bolstering India's defence capabilities?
A: Collaboration is key for innovation. For India to establish a strong and self-sufficient defence ecosystem that designs world-class equipment, strategic partnerships between the government, industry and academia are imperative.
Guided by Dr. S. Christopher, former Chairman of DRDO and CUMI’s R&D Advisor, and Dr. P. Sivakumar, Former Director of Combat Vehicles Research and Development Establishment (CVRDE), as Defence Advisor, some of our collaborations with DRDO and other ecosystem partners include:
CUMI is working with DRDO's Defence Metallurgical Research Laboratory (DMRL) to develop materials to meet higher threat levels for wheeled armoured fighting vehicles. These new lightweight materials will offer superior protection against future threats and significantly improve vehicle performance.
We are in discussions with DRDO to explore technology collaborations in the sphere of aerospace and defence electronics, as well as designing top-grade ballistic materials to combat evolving threats.
CUMI in collaboration with India's leading drone maker, ideaForge Technology, will develop cutting-edge nanomaterial-reinforced composites (like graphene reinforced polymers) specifically for UAVs. These advanced materials boast robust mechanical strength, toughness and stiffness, as well as superior electrical and thermal conductivity.
CUMI has also expressed interest in conducting joint research with DRDO and IIT Delhi for Ballistic Materials. The aim is to develop, test, and validate indigenous ceramic materials for bulletproof jackets and armoured vehicles.
We also signed an MoU with Digital University of Kerala in May 2023, to establish a Centre of Excellence dedicated to graphene research and development. The centre will help harness the immense potential of graphene for large-scale commercialisation in defence and other sectors.
Q. The "positive indigenisation lists" have opened doors for domestic manufacturers. How is CUMI capitalising on this opportunity, especially given your unique role as a producer of materials like Yttria-stabilised Zirconia and graphene? How are you ensuring a secure supply chain to reduce import dependence?
A: CUMI is uniquely positioned to take advantage of this opportunity, especially in defence-critical & futuristic materials as well as nanomaterials. For instance, we are the second-largest producer of silicon carbide in the world.
By being backward integrated with a complete in-house production cycle, advanced R&D capabilities and a deep manufacturing footprint, we have the capability to scale up to efficiently bridge supply gaps in mission-critical areas. We have been able to address key priorities in the area of defence and aerospace – manufacturing critical unavailable materials at globally competitive prices, ensuring timely supply, and meeting stringent regulatory standards.
Our seven-decade legacy in materials science allows us to delve into the vast experience we have built up and deliver precision-built materials with custom engineering, aided by a strong network of vendors and integrators across the value chain.
In order to secure supply and reduce dependence on imports, we have focused our efforts to:
Scale up in-house production of critical unavailable materials such as Yttria-stabilised Zirconia
Intensify R&D efforts internally and through strategic collaboration with academia partners to explore new-age materials such as graphene
Work closely with government agencies such as DRDO to accelerate localisation initiatives while exploring tie-ups to bring in world-class tech. Expand and consolidate the supply chain by getting into partnerships with a diverse set of vendors and integrators. Foster greater innovation in the ecosystem by establishing state-of-the-art labs to promote research and Centres of Excellence (CoEs)
Q. CUMI has been investing in new research labs and Centres of Excellence. What is your R&D strategy, and how does it align with the evolving needs of the defence sector? Are there any specific technological advancements on the horizon that you're particularly excited about?
A: Our R&D strategy is keenly aligned with India’s defence ambitions, evolving requirements of the sector, and a rapidly shifting threat landscape. We work closely with the various labs of DRDO and other partners to ensure our research aligns with the Indian military's specific needs. Investing in cutting-edge facilities – We are constantly pursuing innovations in our key area of advanced ceramics for frontline defence such as bulletproof vests and vehicle armour. Accordingly, we are in the process of expanding production capacity for RBSiC and have the capacity to scale up to entirely meet the growing demand for strategic materials such as YSZ.
Collaborative innovation – We are actively pursuing collaborative research projects with ecosystem partners such as top-tier research-oriented academia partners, government bodies, industry peers, and subsidiaries within the Murugappa Group. This allows us to share our resources and expertise while helping accelerate advancements in materials science for defence applications. Our focus is also on expanding technology partnerships to welcome a host of innovative materials either exclusively for the sector or adapted from other industries to applications in defence and aerospace.
Exploring materials of the future – We are at the forefront of harnessing the immense potential of next-gen materials such as graphene and Phase Change Materials (PCMs). Expanding our repertoire of patents – With a significant pool of R&D specialists and experts, we have witnessed a steady rise in patents, especially for applications in defence.
Focusing on both immediate requirements and future technologies, ensures CUMI’s R&D efforts are empowering the Indian defence sector by reducing import dependence and positioning India as a global leader in advanced defence materials science.
Future tech that we are most excited about are:
Hybrid materials in armour – The focus is on addressing a diverse threat protection range along with being even lighter and more convenient for soldiers and vehicles at the frontlines. Advanced materials science, engineering and nanotechnology are all set to take the stage in an effort to achieve this. Hybrid materials are the future of armour as they combine the best of both worlds – outstanding performance with features such as high fatigue resistance, greater impact strength, and distinctly light in weight, while being economical.
The rise of Graphene – Its exceptional strength-to-weight ratio makes it ideal for developing lighter and stronger aero structures with graphene-reinforced nanomaterials. Graphene coatings could have the potential to enhance stealth capabilities of military aircraft.
Going nano-tech in UAVs – With a multitude of possibilities, UAVs are emerging as key players in the defence arena. Graphene-reinforced structural components for UAVs could potentially exhibit superior mechanical properties at lighter weight or the same weight compared to traditional Carbon Fibre Reinforced Polymers composite components.
Advanced Ceramic Composites – By combining the toughest ceramics such as RBSiC and Zirconia with other materials like fibres or polymers, we can create composites with enhanced properties for aircrafts and armour systems.
3D Printing of Defence Components – CUMI has 3D printing capabilities in ceramics which is critical in investment casting of turbine blades of aircraft as turbine blade cooling channels are getting increasingly complex.
The rise of phase change materials (PCMs) – Passive cooling materials are touted to be the future of defence with their ability to heighten endurance and survivability of soldiers in the toughest terrains and temperature extremes. Through wearable tech such as self-regulating thermal jackets, portable med-kits to preserve and transport life-saving drugs to the remotest areas, non-fossil-fuel based refrigeration to transport perishable food products and store essential drugs, and climate-controlled living quarters.
CUMI has the know-how and competencies to anticipate challenging problem statements and take them from the ‘lab to the field’, with intensive R&D contributing to practical, industry-leading solutions.
Q. The global market for advanced materials in defence is poised for growth. How does CUMI plan to expand internationally while still serving domestic needs? Can you elaborate on any collaborations, like the one with ideaForge Technology, that are accelerating the development of these materials?
A: Materials science and engineering is proving to be a pivotal differentiator in strategic sectors such as defence and aerospace. This has rapidly accelerated the momentum for advanced materials. With our subsidiaries and associates, we enjoy a strong global presence, with operations in India and select global markets. With factories and offices across India, we have the capability to manufacture and fulfil current demand with our pioneering ‘Made in India’ solutions. CUMI will take strategic decisions on where we supply our defence products in future.
Regarding collaborations, several joint R&D projects are currently underway with various DRDO labs. We are also in talks to expand our tech collaborations with DRDO for defence and aerospace applications. We will also establish a CoE in Kerala to pioneer innovations in the ‘wonder material’ graphene. Through a strategic investment in Pluss Advanced Technologies, now a subsidiary of CUMI, we are enhancing our portfolio of future-ready materials for defence.
Q. India aspires to become a global defence manufacturing hub. What role does CUMI envision for itself in this endeavour, and what are your long-term plans to contribute to the growth of India's defence industry?
A: India is emerging as a dominant player in the global defence arena, currently exporting military hardware to 85 countries. In FY 2023-24, defence exports scaled the Rs. 21,000 crore mark, with close to 60% of the contribution from private players.
With an ambitious but achievable defence export target of Rs. 35,000 crores by 2025, we believe that CUMI has a vital role in realising this ambition. As the central link in this system, CUMI is committed to playing a leading role in propelling India towards becoming a self-reliant and globally influential defence manufacturing hub. Materials as the building blocks for innovation in defence and aerospace platforms and systems will hold centrestage.
As part of our long-term plans, we have isolated a few areas for extensive R&D and large-scale manufacture – ceramics for armour, composites for UAVs, TBCs, new-age materials such as graphene, and PCMs.
Towards this end, we are focused on:
Offering the reliable and secure supply advantage to our partners and the defence sector: CUMI's unique strength lies in our complete backward integration. This helps us ensure a secure supply chain, free from external dependencies and fluctuations. Such self-sufficiency allows India to bridge critical material gaps internally and become a strong contender in the global defence exports market.
We adhere to stringent global certifications and quality benchmarks for our materials and processes, opening doors for export opportunities. By sourcing and manufacturing locally, CUMI can supply critical materials at globally competitive prices. Meeting global standards for bulletproof vests like the NIJ 4 compliance, STANAG for vehicle armour, and quality management standards such as the EN9100 certification (also known as AS9100D) fosters trust and positions India as a reliable supplier in the international market.
Future-ready materials: We constantly push the boundaries of what’s possible with a strong focus on pioneering innovation through persistent R&D efforts to develop next-gen materials. Our state-of-the-art research facilities are pushing the boundaries of material science and engineering for defence applications, as we look at constantly raising the bar.
Active collaborations: CUMI is more than just a manufacturer of best-in-class materials. We strive to create an integrated defence ecosystem, collaborating with all stakeholders – from government agencies to research institutions and private sector firms – to ensure a thriving domestic defence ecosystem. This also encourages a culture of knowledge sharing, ultimately accelerating innovation.
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