Deeptech Co. Simpliforge with, Indian Army, Delivers World’s Highest On-Site 3D Printed Structure in Himalayan Range

In a monumental leap for defense infrastructure and construction technology, Simpliforge Creations and IIT Hyderabad, in collaboration with Indian Army represented by Arun Krishnan (who is also a PhD student at IIT-Hyderabad), have successfully delivered India’s first on-site 3D printed protective military structure at a staggering altitude of 11,000 feet above sea level in Leh under Project PRABAL.

This marks the world’s highest-ever in-situ 3D construction printing feat, accomplished under the extreme high altitude and low oxygen (HALO) conditions.

Under the guidance of Prof. K.V.L. Subramaniam of IIT-Hyderabad, Simpliforge Creations and IIT-Hyderabad Teams developed specialized 3D printing technology capable of operating under extreme environmental conditions. This innovation enabled the construction of a form-optimized protective bunker using locally sourced materials, completed over a total printing time of fourteen hours.

The PRABAL initiative showcases how homegrown technology and academic-industry collaboration can push the boundaries of construction science. The deployment of this 3D printed bunker is not only a first-of-its-kind in India but also sets the stage for rapid, on-site, deployable infrastructure in challenging terrains, further strengthening the country’s defense preparedness.

This groundbreaking project marks a convergence of engineering innovation, military utility, and the Make-in-India spirit—paving the way for future-forward infrastructure solutions.

Speaking on the occasion, Simpliforge Creations CEO Dhruv Gandhi stated "Executing this project in the high-altitude, low-oxygen environment of Ladakh was an immense operational challenge—for both our team and our machines. The Robotic printer system was set-up and commissioned in under 24 hours proving its agility & mobility. The reduced oxygen levels affected everything from power systems performance, which were delivering lower energy output than they would on normal plains, to human efficiency. The low humidity and high UV posed challenges in integrity of the built material. Despite these constraints, we were able to meet our production targets and deliver a robust structure within a record timeframe of 5 days.”

Prof KVL Subramaniam – IIT Hyderabad said, "One of the most critical aspects of this project was the development of specially engineered materials tailored to perform in extreme environmental conditions. Operating at high altitudes with low oxygen levels, low humidity and significant thermal variations required not just structural innovation, but also material science at its finest. Our team at IIT Hyderabad, in collaboration with Simpliforge Creations, designed a concrete mix that could be 3D printed on-site while offering superior mechanical performance, durability, and resilience. Before deployment, we conducted vigorous testing at IIT Hyderabad’s advanced facilities, including comprehensive studies on local sand and aggregates sourced from the region, rheology of mix. Understanding the material behaviour under simulated environmental stresses allowed us to optimize the mix design for on-site usage. This material innovation was fundamental to achieving the desired strength and structural integrity within such a challenging context."

Arun Krishnan commented, "Project Prabal was conceptualized and initiated during my M.Tech program at the Indian Institute of Technology Hyderabad. Several teams and companies had attempted to bring 3D printed construction to the high-altitude terrain of Leh, but the extreme conditions of Ladakh proved to be a formidable challenge. It was the unmatched synergy between Simpliforge Creations and IIT Hyderabad that finally made it possible. Their technical depth, adaptability, and relentless focus on innovation enabled the successful execution of Project PRABAL. Together, we didn’t just build a structure—we proved that indigenous, cutting-edge technology can overcome even the harshest operational environments and deliver tangible impact for our armed forces. The printed structure has undergone rigorous trials."

Hari Krishna Jeedipalli, MD - Simpliforge Creations said, “we've been pushing the boundaries of additive construction since 2022—from building India’s first 3D printed bridge, to the world’s first 3D printed place of worship, and the Indian Army’s first in-situ 3D printed medical facility using locally available material. Each project has been a leap forward, and this bunker in Ladakh marks a crucial milestone in our journey towards extra-terrestrial”.

“Looking ahead, we envision commercialising this technology for remote terrain applications and extending this beyond Earth—towards space habitats on the Moon and Mars. Printing in the extreme, open conditions of Ladakh has given us vital insights and validation for operating in extra terrestrial environments. It’s more than construction—this is a stepping stone on our journey into space deep tech. added Mr Hari

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.

Simpliforge Launches India’s 1st State-of-the-Art Robotic Concrete 3D Printer at Charvitha Meadows

Minister for Finance, Health and Family Welfare, Govt. of Telangana, T. Harish Rao, inaugurated the Robotic Construction 3D Printer in Siddipet

Simpliforge Creations, provider of additive manufacturing solutions, today launched their first-of-its-kind, state-of-the-art Robotic Construction 3D Printer. Claimed to be India’s first and South Asia’s largest Robotic Construction 3D printer, the printer was inaugurated by Sri Thaneeru Harish Rao, Hon’ble Minister for Finance, Health and Family Welfare, Govt. of Telangana, at Charvitha Meadows in Siddipet. Present along with the Minister were Mr. Amit Ghule, Founder & COO, Simpliforge Creations, and Mr Dhruv Gandhi, Founder & CEO, Simpliforge Creations who shared the innovative aspects of the machine and spoke about plans for innovative constructions to be handled by the robotic arm printer.

Construction 3D Printing is a technology set to address the unique housing needs of India for remote constructions as well as innovative designs. Simpliforge’s Robotic Arm Construction 3D Printer is not only the largest Construction 3D Printer in India but also the first of this size in South Asia. The 3D Printer can print landscaping elements, furniture, statues, and wall façade, among others, to full-scale civil structures. The printer is capable of working with environment-friendly materials like geopolymers and clay, with Simpliforge launching its proprietary construction material ‘SIMPLICRETE’ as well. The advantages of Additive Manufacturing being minimal wastage, shortened supply chains, optimal resource utilization and decentralized manufacturing are being brought to the construction Industry.

Minister Harish Rao launching the robotic arm

Amit Ghule-COO and Dhruv Gandhi-CEO Simpliforge Creations with team

Speaking on the occasion, Hon’ble Minister Harish Rao said, "Innovation can happen anywhere, it need not be a Tier I Metro city, but even a small town like Siddipet. The 3D printer is one such milestone initiative. It gives me immense joy to be launching this state-of-the-art technology at Charvitha Meadows. I congratulate the entire team of Simpliforge for this remarkable landmark and wish them all the best to continue to contribute to the needs of their industry and position Siddipet as the hub of such advanced technology innovations."

Expressing his delight on the launch of this innovation, Mr. Amit Ghule, Founder & COO, Simpliforge Creations, said, “We are humbled by the presence of our Hon’ble Minister Harish Rao garu for launching our project. The current 3D printer can create structures up to 7m in size, making it the largest Robotic Concrete 3D Printer in India, and in fact, the entire South Asian region. Further, the range of the printer can be increased as required. Robotic Concrete 3D printer provides better design versatility and freedom to the designers whilst also being easy to deploy at project sites than gantry style printers, making it attractive to designers and project developers alike."

"Charvitha Meadows is a one-of-its-kind and new-age gated community with plots and villas in Siddipet, Telangana. It’s a futuristic world designed with a sustainable approach for holistic living. We are proud to collaborate with Simpliforge and excited to embark on this remarkable journey towards innovation", said Hari Krishna J, MD & CEO at Apsuja Infratech (Charvitha Meadows).

Mr Dhruv Gandhi, Founder & CEO, Simpliforge Creations adding more details on the technology said, “At Charvitha Meadows, we are printing a number of artistic elements for its Sanjeevani Park, positioning it to be India’s first park of its kind. The design philosophy of Charvitha Meadows is sustainable living with amalgamation of futuristic technologies. This Robotic 3D printing technology is chosen considering the ecological advantages of the technology and the design freedom it offers. We greatly appreciate the Telangana Government for always being the pioneer in promoting innovative technologies and also working towards setting up a ‘National Centre for Additive Manufacturing’, showing the government’s proactive interest in pushing this technology ahead.”

Amit Ghule (COO) & Dhruv Gandhi (CEO) Simpliforge Creations and Hari Krishna J

Equipped with a large materials library, niche design expertise and sound domain knowledge for technology applications, Simpliforge Creations aims to expand globally with its technology. The company envisions constructing unique civil structures while developing robotic technology to enable smart construction in India and abroad. This technology also gives design freedom to architects and structural engineers to experiment with unique structures for novel construction.

ABOUT SIMPLIFORGE CREATIONS

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 such as prototyping, prosthetics, jewellery, medical devices, etc. 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 aforementioned domains.