In collaboration with the Indian Institute of Technology Hyderabad (IIT-H) and the start-up Simpliforge Creations, the Indian Army has completed the country’s first on-site 3D-printed military structure as part of the PRABAL project. The protective bunker was built in Leh, Ladakh, at an altitude of around 3,350 meters (11,000 feet) – under extreme environmental conditions with low oxygen concentration, strong UV radiation and large temperature fluctuations.
According to the project management, this is the world’s highest in-situ 3D printing construction to date. The total printing time was just 14 hours and completion, including post-processing, was achieved within five days. The basis was a specially developed concrete mix, which was adapted to the local climatic conditions under the direction of Prof. K.V.L. Subramaniam from IIT-Hyderabad. The decisive factor was the combination of rheological tests, the analysis of local aggregates and the optimization of the water-binder ratio.
The printer used had to work under difficult conditions: low air pressure, low humidity and strong UV radiation impaired both material processing and hardware functions. Nevertheless, according to Simpliforge, the robotic system was installed and operational within 24 hours of arrival. CEO Dhruv Gandhi spoke of an operationally and technologically challenging deployment.
In a military context, additive manufacturing offers advantages such as faster construction times, optimized material usage and increased autonomy in remote regions. The project is regarded as a technology demonstrator for potential follow-up applications, such as temporary accommodation, storage buildings or defense facilities that can be flexibly erected on site.
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