India’s electric vehicle (EV) industry is witnessing unprecedented growth, driven by ambitious government policies and an increasing shift toward sustainable mobility. According to Business Standard, EV sales in India increased by 22.8% year on year, with 156,199 vehicles sold in August 2024. A total of 127,206 vehicles were sold in August 2023, indicating a considerable increase in EV adoption over the previous year, with two-wheelers accounting for approximately 80% of the market. Government initiatives such as the Faster Adoption and Manufacturing of Hybrid and Electric Vehicles (FAME) program, together with state-level subsidies and tax breaks, helped accelerate this trend.
“Imagine the scenario, when the number of two-wheelers reaches the number of passenger vehicles, the outlook for OEMs and essential part makers in India would change dramatically.”
Despite this rapid growth, India continues to rely heavily on imported components, particularly crucial drivetrain systems. According to research, over 60-70% of EV components, including motors, controllers, and gearboxes, are sourced from international suppliers in CHINA, GERMANY, and the United States, resulting in higher production costs and minimal local value addition.
Drivetrain Technology in EVs: The Heart of EVs
At the core of EV performance is the drivetrain system, which converts motor power into motion. Unlike internal combustion engine (ICE) vehicles, which require complex multi-speed gearboxes, EVs rely on drivetrain simplicity to achieve peak performance. This is where single-speed gearboxes are essential. These special type of gearboxes provide smooth torque transmission, high efficiency, and low energy losses, making them perfect for use in EVs.
3 Factors that makes the single-speed gearboxes rule the EV trend
Now, the question is, what Indian gear manufacturer can do to master the single-speed gearboxes (drivetrain system) locally?
Mastering the design and construction of single-speed gearboxes is more than an opportunity for Indian gear makers; it is a necessity. They may considerably reduce production costs, increase the competitiveness of Indian EVs, and strengthen their place in the global EV supply chain by lowering reliance on imports and encouraging local innovation. The ability to spearhead this transformation will determine India’s future of sustainable mobility.
Precision engineering is the first challenge for Indian gearmakers while building single-speed gearboxes. To ensure quiet and vibration-free operation, single-speed gearboxes for electric vehicles need gear teeth with tolerances as close as ±5 microns. Achieving this requires high-precision CNC machining and metrology equipment such as CMMs and gear analysers. Advanced finishing procedures, including honing, lapping, or superfinishing, ensure smooth operation. Consistent heat treatment, including case hardening and carburising, gives the requisite hardness and wear resistance (~58-62 HRC).
The second most difficult challenge is selecting materials. High-strength alloys such as 16MnCr5 and 20MnCr5 offer toughness and fatigue resistance. Shot peening and coatings such as DLC improve thermal stability and wear resistance. Lightweight materials like composite polymers and aluminium alloys improve energy efficiency, but they all require material testing facilities for validation.
Lastly, the manufacturing scale, Scaling manufacturing in India necessitates infrastructural enhancements that include automated machinery, such as robotic gear hobbing and skiving. Durable gear, such as PCD cutting tools and carbide-tipped hobs, provides accuracy. Implementing Industry 4.0 technologies like machine monitoring, digital twins, and predictive maintenance improves production efficiency and reduces errors. Ultimately, Indian gear makers must employ sophisticated technologies, automate production, and prioritise material innovation to fulfil and take advantage of the rising EV demand as an essential driving component manufacturer. Training in these areas will help Indian manufacturers bridge the talent gap and position them as leaders in this transforming industry.
Mastering single-speed gearboxes for EVs will considerably benefit the Indian economy. India can play an important part in the burgeoning EV supply chain by increasing its domestic manufacturing capabilities. This can have a knock-on impact, boosting job growth not only in manufacturing but also in sophisticated R&D sectors. As Indian enterprises invest in gear technology, there is a significant opportunity for talent development, technological innovation, and industrial collaboration. The end outcome is a stronger economy with increased local value addition and less reliance on imports.
As worldwide demand for electric vehicles grows, India has the opportunity to establish itself as a competitive participant in the EV drivetrain technology market. Mastering single-speed gearboxes might position India as a key provider of low-cost, high-performance components, allowing for cost-effective electric vehicle manufacture. This technological knowledge will not only give India a competitive advantage in the global market, but will also boost its standing in the rapidly developing EV ecosystem. Manufacturers such as Tata Motors and Mahindra Electric are already making progress in EV development, and future breakthroughs in local gearbox production can help India maintain its position as a pioneer in sustainable automotive solutions.
Focussing on mastering single-speed gearboxes is consistent with India’s overall sustainability goals, which include shifting to cleaner mobility solutions. As the Indian government promotes transportation electrification, minimising reliance on imported drivetrain components becomes increasingly important. Locally built, energy-efficient gearboxes will minimise carbon emissions by encouraging the widespread use of electric vehicles. Upon the trend of EVs, the rise of self-driving cars is increasing the demand for precise and economical gear systems, with single-stage gearboxes emerging as a critical component. These self-driving cars require strong, high-efficiency drivetrains that reduce mechanical complexity while optimising performance for smooth, predictable operation—something single-speed gearboxes excel at.
Furthermore, by investing in sustainable manufacturing processes and renewable energy-powered production lines, the gear manufacturing industry may connect with India’s carbon reduction goals. India may gain a competitive edge in the global EV supply chain. As EVs transform the transportation industry, mastering this technology is more than a technical accomplishment; it is a strategic move that enables Indian businesses to dominate the future of mobility. To remain at the forefront, Indian businesses must innovate, partner with global leaders, and invest in cutting-edge research and manufacturing infrastructure. These important developments hold the key to India’s future mobility and economic success.
Conclusion
The future of the automotive industry, particularly the rise of electric and driverless vehicles, will necessitate high-performance, cost-effective, and environmentally friendly drivetrain technologies. Mastery of single-speed gearboxes is critical in satisfying these requirements. This industry sill has a space togrow exponentially in India and Indian manufacturers have the opportunity to take the lead in this disruptive shift by exploiting technology improvements and local experience to not just support the local demands but become global providers of next-generation EV drivetrains. The strategic focus on developing these technologies will not only help India achieve its EV targets, but will also strengthen the country’s position in the global race for green, autonomous mobility solutions. By investing in innovation, collaboration, and research, Indian gear manufacturers can put themselves at the forefront of the global EV revolution, assuring long-term success and sustainability in the constantly changing automotive industry.
