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Thu, Aug 21, 2025
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Ola Electric's Gigafactory: Powering India's EV Future with In-House Innovation

Sarah J4 min read
Ola Electric's Gigafactory: Powering India's EV Future with In-House Innovation


Ola Electric is spearheading India's electric vehicle (EV) revolution with its state-of-the-art Gigafactory located in the Krishnagiri district of Tamil Nadu, on the outskirts of Bangalore. This expansive 115-acre facility is dedicated to the manufacturing of lithium-ion cells and is touted as India's first Gigafactory.




India's First Gigafactory: A Hub of Complexity and Cleanliness The Ola Gigafactory is an extremely complex manufacturing facility, requiring exceptionally clean rooms where even moisture, sweat, hair, or dirt cannot enter the atmosphere. This level of precision is comparable to semiconductor manufacturing processes, making it one of the most intricate in the world.


The Heart of EVs: The 4680 Lithium-Ion Cell At the core of Ola Electric's ambition is the 4680 lithium-ion cell, described as "the heart of EVs". Beyond electric vehicles, this small cell is envisioned as the "energy platform of the future," capable of powering diverse applications such as drones, humanoids, home energy storage devices (like inverters replacing lead-acid batteries), and even grid storage alongside solar plants.


Impact on Ola Electric's Products and Margins The 4680 cells are set to power Ola scooters this quarter (Q2: July-September), with the first products delivered to customers during Navratri. Manufacturing these cells in-house will significantly improve Ola Electric's margins over the next 12 months, as they move away from importing this crucial component. All upcoming Ola products, including Gen 3 scooters, motorbikes, and future offerings, will utilise the 4680 cells. In-house cell production offers several strategic advantages:

  • Technology Control: Ola gains control over the technology, which defines product performance, including charging speeds, range, and thermal performance.
  • Supply Chain Resilience: It reduces dependence on external suppliers or geopolitical factors that might throttle supplies.
  • Faster Development & Customisation: The ability to build the next generation of cell technology faster and customise cells for different products, such as motorcycles or performance bikes, is enhanced.
  • All cells produced are BIS certified.


A Glimpse into the Manufacturing Process The Gigafactory process is highly automated and precise:

  • All-Women Workforce: A notable highlight is that the Gigafactory is an all-women facility, currently employing around 500 women and scaling up to 1,000. These women operate complex machines, engaging in high-skill level jobs rather than manual labour. Many are engineering graduates.
  • Cathode Production: The process begins with cathode making, where raw materials are processed and wound into electrode rolls. These raw materials are sourced from multiple countries, including China, Japan, Korea, and Australia (a major producer of lithium and manganese).
  • Slitting: Large electrode rolls are then precisely slit into smaller "daughter rolls" with micron-level accuracy.
  • Assembly and Jelly Roll Creation: In the assembly process, the cathode, anode, and a separator are combined into a "jelly roll".
  • Multi-Stage Production: Making a cell involves almost 20 more processes after the jelly roll stage. This includes flattening sides, intricate welding to attach the lid, and taping sides to ensure vacuum and air-proofing.
  • Electrolyte Filling and Charging: The cells are initially open for electrolyte filling, after which they are sealed with a plug and undergo a 10-day charge/discharge "hibernation" cycle.
  • Quality Assurance with AI: Every single cell undergoes an X-ray inspection, with AI imaging used to detect any deviations in critical parameters like the gap between cathode and anode layers. This ensures micron-level accuracy and is essential for the factory's operation.
  • Production Capacity: The factory boasts a throughput of 1 to 2 lakh cells per day. Approximately 40 of these cells go into one scooter battery pack.
  • Investment: The 5 GWh capacity of the Gigafactory will require an investment of approximately $400 million, much of which has already been invested through equity and pre-IPO debt.


Moving Towards Rare Earth-Free Motors Ola Electric is also working on a rare earth-free motor, specifically a ferrite magnet motor. This initiative comes as China holds a near monopoly on rare earths, which are essential for current motor technologies. Ola began this journey two years ago and is ready for production next quarter, aiming to de-risk its supply chain from rare earth dependency. The long-term direction for motor technology is to reduce or eliminate magnets by using copper wire with electricity to create electromagnets. In the short term, Ola has already diversified its magnet sources across multiple countries and produces motors in-house, mitigating immediate production impacts.


Market Dynamics and Future Outlook The EV market in India has seen an aggressive ramp-up, with scooter adoption growing from almost zero to about 20% in just four years. While currently in a phase of consolidation, Ola anticipates another steep ramp-up driven by technology progression, cost reduction, and improved range and charging speeds.


Ola Electric entered the market later than some rivals but was the first to scale, building significant vertical integration, factory scale, and consumer mind share. Ola has sold 1.2 million two-wheelers to date, significantly outpacing its closest competitor. The company has shifted its strategy towards profitable growth, focusing on deep vertical integration, technology development, and a "DNA of technology" to build good products and ensure profitability. Ola aims to achieve a 25-30% market share in two-wheeler EVs with high margins.


Bhavish Aggarwal, founder of Ola Electric, states that their vision for the cell Gigafactory extends beyond their own products; it is intended to be an energy platform for India, with cells potentially supplied to other startups and companies for drones, robotics, energy storage, and other automotive products.


Aggarwal draws inspiration from global EV leaders like Tesla and BYD for their vertical integration, high margins, and product differentiation, as well as cell companies like CATL and LG for their world-class processes and innovation. He believes it's "never too late" for India to start and scale up in these frontier technologies, aiming to "leapfrog" existing advancements.

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Startup Europe India Network (SEINET) is an exclusive, invite-only platform connecting science and technology scale-ups, industry leaders, and investors from Europe and India to accelerate cross-border growth through sales, partnerships, and M&A. www.startupeuropeindia.net

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Sarah   J

Sarah J

Sun, Sep 6, 2026

Isar Aerospace Reaches Orbit: What It Means for Europe's Commercial Rocket Industry

German company Isar Aerospace has successfully launched its Spectrum rocket into orbit, marking an important milestone for Europe's privately developed launch industry. How does Spectrum compare with SpaceX, ISRO, China and Russia, and why is the launch significant?On 5 September 2026, German aerospace company Isar Aerospace successfully launched its Spectrum rocket from Andøya Spaceport in Norway.The flight reached orbit and deployed its customer payloads. It was the second flight of Spectrum, following an unsuccessful first launch in March 2025.The significance of the mission is specific: Spectrum is a privately developed European orbital launch vehicle that has now demonstrated successful orbital flight.This is different from saying that Europe has developed a rocket comparable in capability to the largest launch vehicles operated by SpaceX, China, India or Russia.The comparison becomes clearer when the launch vehicles and the underlying industrial models are examined separately.1. What is Isar Aerospace?Isar Aerospace is a German private aerospace company founded in 2018 and headquartered in Ottobrunn, near Munich.Its launch vehicle is Spectrum, a two-stage rocket designed primarily to launch small and medium-sized satellites into low Earth orbit and sun-synchronous orbit.Key specifications published by Isar include:Specification Spectrum Height 28 metres Diameter 2 metres Stages 2 LEO payload Up to 1,000 kg SSO payload Up to 700 kg First-stage engines 9 Aquila engines Second-stage engines 1 Aquila engine Propellant Liquid oxygen + propane Current first stage ExpendableThe September 2026 flight was therefore an orbital demonstration and commercial launch milestone, rather than the introduction of a heavy-lift rocket.2. How does Spectrum compare with SpaceX?The most useful comparison is with Falcon 9, because Falcon 9 is SpaceX's principal commercial orbital launcher.Isar Spectrum SpaceX Falcon 9 Height 28 m 70 m LEO payload Up to ~1 tonne Up to 22.8 tonnes Stages 2 2 First-stage engines 9 9 First-stage reuse No Yes Primary market Small/medium satellites Broad commercial and government missions Orbital status Successful orbital flight demonstrated in 2026 Mature operational systemSpaceX's Falcon 9 lifts up to 22,800 kg to LEO when flown expendable (about 17,500 kg when the booster is recovered).On published payload capacity, Falcon 9 can therefore place more than 20 times as much mass into LEO as Spectrum.The two rockets also have different launch architectures.Spectrum is currently an expendable launcher. Falcon 9's first stage is designed for recovery and reuse.This distinction affects the economics and operational model of the two systems, but the most straightforward factual comparison is that they occupy different payload classes and are at different stages of operational maturity.3. How does Spectrum compare with India's ISRO?India has a much longer-established orbital launch programme.The Indian Space Research Organisation (ISRO) operates the PSLV, GSLV and LVM3 launch vehicle families.The LVM3 is particularly useful for comparison.ISRO's own published specifications give LVM3 a payload capability of approximately 8,000 kg to a 600 km circular low Earth orbit. The vehicle is approximately 43.5 metres tall with a liftoff mass of about 640 tonnes.The comparison is therefore:Spectrum ISRO LVM3 Height 28 m ~43.5 m LEO payload class ~1 tonne ~8 tonnes Stages 2 3 Reusable No No Development model Private company Indian national space programme Operational history Orbital success demonstrated in 2026 Multiple successful missions since 2017ISRO has also used LVM3 for commercial satellite launches, including missions for OneWeb.The two systems therefore differ both in payload class and in their institutional origins.4. How does it compare with China's rockets?China operates a large family of Long March launch vehicles covering a wide range of payload classes.One of the country's largest operational launchers is Long March 5.Long March 5 has a published payload capability of approximately 25 tonnes to low Earth orbit.That puts Long March 5 in a completely different payload category from Spectrum.Spectrum Long March 5 LEO payload ~1 tonne ~25 tonnes Stages 2 2 core stages plus strap-on boosters Reusable No No Launch system Private European company Chinese national launch system Major applications Commercial satellite launches Large spacecraft, space infrastructure and exploration missionsChina's launch capability also includes human-spaceflight and lunar missions, alongside a growing commercial launch sector.Therefore, the significance of Spectrum's flight should not be measured against China's overall space programme in terms of technical capability.The relevant development is instead the emergence of another European commercial launch provider.5. How does it compare with Russia?Russia has extensive orbital-launch heritage through the Soviet and Russian space programmes.The Soyuz family is one of the world's longest-operating orbital launch systems.The comparison is therefore fundamentally different from the comparison with Isar.Russia's launch capability is based on decades of accumulated development and operational experience, while Isar represents a new private European entrant into orbital launch services.Russia also operates launch vehicles across several payload classes.Consequently, Spectrum's successful orbital flight does not represent a replacement for Russia's existing launch capabilities. It represents the addition of a new European commercial launch capability.6. Europe already had rockets. So what is different about Isar?This is perhaps the most important factual distinction.Europe did not previously lack orbital launch vehicles.The European launcher programme includes:Ariane 6Europe's principal heavy launcher.Ariane 6 is available in two configurations:Ariane 62Ariane 64The Ariane 64 configuration can carry approximately 21.6 tonnes to low Earth orbit, roughly double the Ariane 62 configuration's capacity of about 10.3 tonnes.Vega-CA smaller European launcher designed for missions including Earth-observation and other satellites.Vega-C's payload capability varies according to orbit, with a reference payload capacity of approximately 2.3 tonnes to a 700 km polar orbit.Spectrum therefore isn't Europe's first orbital rocket.It is significant because it represents a privately developed European launcher operating outside the traditional Ariane/Vega programme structure.7. The European commercial-launch landscape is expandingIsar Aerospace is also not the only European company developing an orbital launcher.Germany's Rocket Factory Augsburg (RFA) is developing RFA ONE.Spain's PLD Space is developing the Miura family of launch vehicles.The European Space Agency has established programmes intended to support the development of commercially operated European launch services.ESA's European Launcher Challenge is specifically designed to establish additional European commercial launch-service providers and increase European access to space. Isar Aerospace was one of the operators selected for the programme, and its contract requires an orbital launch no later than 2027, a milestone the September 2026 flight has already satisfied.The development can therefore be viewed as an expansion from a European launcher structure dominated by institutional programmes toward a structure that includes multiple privately developed launch companies.8. What has actually been proven by the September 2026 flight?It is useful to separate what the flight demonstrates from what remains to be demonstrated.Demonstrated1. Orbital capabilitySpectrum successfully reached orbit.2. Private European developmentThe vehicle was developed by Isar Aerospace rather than being an Ariane or Vega government/industrial programme.3. Commercial launch capabilityThe mission carried customer payloads.4. European launch infrastructureThe launch took place from Andøya Spaceport in Norway.Not yet demonstrated by this flightA single successful flight does not establish:long-term launch reliabilityhigh launch cadencelarge-scale rocket manufacturingcommercial profitabilityreusabilityFalcon 9-level launch economicslarge-scale constellation deployment capabilityThose are separate performance and business metrics that require additional operational evidence.9. The numbers put the achievement in perspectiveA simple payload comparison illustrates the different positions of the major launch systems:Launcher Approximate LEO payload Reusable first stage? Isar Spectrum ~1 tonne No Vega-C ~2.3 tonnes to 700 km polar orbit No ISRO LVM3 ~8 tonnes to 600 km orbit No Ariane 64 ~21.6 tonnes to LEO No SpaceX Falcon 9 ~22.8 tonnes to LEO Yes China Long March 5 ~25 tonnes to LEO NoThese figures should not be interpreted as a ranking of the overall space programmes. Payload capacity depends on the target orbit and mission configuration, and launch vehicles are designed for different markets.But they show clearly that Spectrum belongs to a smaller payload class than Falcon 9, Ariane 64, LVM3 and Long March 5.10. Why the launch matters for EuropeThe factual significance is therefore not primarily the size of Spectrum.It is the change in the composition of Europe's launch industry.Europe now has:Institutional launch systemsAriane 6Vega-Cand an expanding group of:Privately developed commercial launch systemsIsar AerospaceRocket Factory AugsburgPLD Spaceother emerging European providersThis creates a broader European launch ecosystem with multiple companies developing their own vehicles, propulsion systems, manufacturing processes and commercial customer bases.For European governments and institutions, additional domestic launch providers can also provide another source of launch capacity for European satellites.That is relevant to Europe's objective of maintaining autonomous and resilient access to space. ESA and the European Commission have both identified this as an important element of European space policy.11. The significance in one sentenceThe most factually precise way to describe the September 2026 achievement is:Isar Aerospace has demonstrated that a privately developed European orbital launch vehicle can successfully reach orbit and deliver customer payloads, adding a new commercial-launch capability to Europe's existing Ariane and Vega programmes.It is not evidence that Spectrum has the launch capacity of Falcon 9, LVM3, Ariane 6 or Long March 5.It is evidence that Europe's launch sector now includes a privately developed orbital rocket that has successfully completed an orbital mission.The next stage is operational: repeated launches, reliability, manufacturing scale, pricing, customer demand and the development of future launch vehicles.That is where the significance of Isar Aerospace will ultimately be measured.
Sun, Sep 6, 2026
Isar Aerospace Reaches Orbit: What It Means for Europe's Commercial Rocket Industry
Sarah   J

Sarah J

Sat, Jul 18, 2026

India has become the third country, after the United States and China, to achieve orbital launch capability through a privately developed rocket

Hyderabad-based Skyroot Aerospace successfully launched Vikram-1, India’s first privately developed orbital launch vehicle, from the Satish Dhawan Space Centre in Sriharikota on July 18, 2026. The rocket lifted off at 12:05:30 p.m. Indian Standard Time as part of Mission Aagaman, meaning “arrival.”Around 15 minutes after launch, Vikram-1 successfully deployed payloads into a low Earth orbit at an altitude of approximately 450 kilometres. ISRO confirmed that two satellites—Skyroot’s SCOPE and a satellite from Grahaa Space—were injected into orbit. Other payloads remained attached to the upper stage to conduct in-orbit experiments.India has operated orbital launch vehicles through the Indian Space Research Organisation since the successful launch of the Rohini satellite aboard SLV-3 in 1980. The significance of Mission Aagaman is that Vikram-1 was developed and launched by a private Indian company, although ISRO and the Indian National Space Promotion and Authorisation Centre provided facilities, technical support, safety oversight and regulatory clearances.The Vikram-1 RocketVikram-1 is a small-satellite launch vehicle standing approximately 22 metres tall. It is designed to carry payloads of up to 350 kilograms into low Earth orbit.The four-stage vehicle consists of three solid-fuel stages and a liquid-fuel orbital adjustment module. Its upper stage is powered by a 3D-printed liquid engine and is designed to support precise orbital deployment. The rocket also incorporates carbon-composite structures, avionics and thermal-protection technologies developed by Skyroot.The Vikram launch-vehicle series is named after Vikram Sarabhai, the scientist widely regarded as the father of India’s space programme.Skyroot is positioning Vikram-1 as a dedicated and rideshare launcher for small satellites requiring customised orbital deployment. The company argues that such missions can provide customers with greater control over launch timing and orbital destination than travelling as secondary payloads on larger rockets.Payloads and ExperimentsThe mission carried multiple customer payloads and in-orbit experiments from Indian and international organisations.ISRO has officially confirmed that two satellites, SCOPE and Grahaa, were successfully placed into low Earth orbit. The remaining payloads were carried on the upper stage for in-orbit experiments.Before launch, the announced mission manifest included:Skyroot’s SCOPE satelliteGrahaa Space’s SOLARAS S3 satelliteA technology demonstration from German space company DCUBEDEmbrace, a robotic arm experiment developed by Cosmoserve Space for orbital-debris captureThe announced manifest also included symbolic payloads: a floral-shaped artwork called Cosmic Bloom and a miniature 18-karat gold rocket honouring Indian scientific figures C.V. Raman, Vikram Sarabhai and A.P.J. Abdul Kalam. These items were listed before launch, but official post-launch statements have not separately confirmed the operational status of every individual experiment.Mission Aagaman was intended to test Vikram-1’s propulsion, avionics, telemetry, stage separation, guidance, navigation and control systems under actual flight conditions. Skyroot described the flight as the first of a planned series of development missions ahead of routine commercial operations.From Vikram-S to Vikram-1Skyroot Aerospace was founded in 2018 by former ISRO engineers Pawan Kumar Chandana and Naga Bharath Daka.The company completed its first spaceflight in November 2022 with Vikram-S, a suborbital technology-demonstration rocket launched under Mission Prarambh. That flight made Skyroot the first private Indian company to launch a rocket into space from Indian soil, although Vikram-S did not enter orbit.Vikram-1 represents a significantly more demanding technical achievement. Reaching orbit requires a rocket not only to climb above Earth’s atmosphere but also to accelerate its payload to the horizontal velocity needed to remain in orbit. The vehicle must complete a carefully timed sequence of propulsion, stage-separation and navigation operations before deploying its payloads.India opened more of its space sector to private participation in 2020 and subsequently established a framework through IN-SPACe for private companies to access ISRO facilities and technical expertise. For Vikram-1, ISRO supported solid-motor casting and testing, liquid-engine testing, vehicle integration, trajectory analysis and launch-pad operations.Reaction and Next StepsPrime Minister Narendra Modi called the successful launch a defining moment in India’s space journey. He said growing private-sector participation was opening new frontiers and accelerating innovation, adding that the achievement would encourage young people to “dream bigger and innovate fearlessly.”Skyroot said Mission Aagaman was a test flight and that it expects to conduct additional development flights before beginning routine commercial launches. The company ultimately aims to provide frequent, dedicated launch services for small satellites.The achievement does not replace India’s longstanding government space-launch capability. Instead, it expands the country’s space ecosystem by demonstrating that an Indian private company can independently develop an orbital-class launch vehicle and successfully place satellites into orbit with institutional support from ISRO and IN-SPACe.Sources: Indian Space Research Organisation, Prime Minister’s Office of India, Reuters, Skyroot Aerospace and Space.com.Image courtesy: Skyroot AerospaceSEINET is an execution focused network for operators building partnerships and growth in EU-India-UK corridor in four key clusters - Space, Deep Tech, Defense and Energy. Apply to sign up www.startupeuropeindia.net
Sat, Jul 18, 2026
India has become the third country, after the United States and China, to achieve orbital launch capability through a privately developed rocket
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Sarah J

Sat, Jul 18, 2026

Skyroot's Vikram-1 Makes History as India's First Privately Developed Orbital Rocket Reaches Space

Sat, Jul 18, 2026
Skyroot's Vikram-1 Makes History as India's First Privately Developed Orbital Rocket Reaches Space