SOURCE: AFI
In a groundbreaking achievement for defense infrastructure, the Indian Army, in collaboration with Hyderabad-based deep-tech startup Simpliforge Creations and the Indian Institute of Technology (IIT) Hyderabad, has constructed the world’s highest on-site 3D-printed structure—a protective military bunker—at an altitude of 11,000 feet in Leh, Ladakh. Completed in just 14 hours of printing time under Project PRABAL, this feat marks a monumental leap in rapid, resilient construction technology, showcasing India’s innovation prowess in extreme environments and bolstering its strategic preparedness along the Line of Actual Control (LAC).
Named PRABAL (Pioneering Rapid Additive Building in Adverse Landscapes), the initiative represents a pioneering effort to deploy advanced 3D printing technology for military infrastructure in high-altitude, low-oxygen (HALO) conditions. The bunker, designed to protect troops from harsh weather and potential threats, was constructed using a specialized robotic 3D printing system and a custom-engineered concrete mix tailored to withstand Ladakh’s sub-zero temperatures, low humidity, and high ultraviolet (UV) exposure. The structure’s form-optimized design, built with locally sourced materials like sand and aggregates, enhances its durability while reducing logistical dependencies.
The project was spearheaded by Arun Krishnan, a PhD student at IIT Hyderabad and an Indian Army representative, under the guidance of Professor K.V.L. Subramaniam from IIT-H’s Civil Engineering Department. “Project PRABAL was conceptualized during my M.Tech program at IIT Hyderabad,” Krishnan said. “Several teams had tried 3D printing in Ladakh’s extreme terrain, but the conditions were daunting. The synergy between Simpliforge Creations and IIT Hyderabad made this breakthrough possible, proving that indigenous technology can deliver tangible impact for our armed forces.”
Ladakh’s high-altitude environment posed immense challenges, with oxygen levels at 40-50% of sea-level norms, temperatures plunging below freezing, and intense UV radiation affecting both human and machine performance. “Executing this project was an operational marathon,” said Dhruv Gandhi, CEO of Simpliforge Creations. “Our robotic printer was set up in under 24 hours, despite reduced power output and material integrity issues caused by low humidity. We completed the structure in a record five days, with 14 hours of actual printing time.”
The bunker’s construction involved rigorous pre-deployment testing at IIT Hyderabad’s advanced facilities, where the team studied local materials and simulated environmental stresses to optimize the concrete mix. The result is a bullet-resistant structure with a geometric-patterned façade—achievable only through 3D printing—that minimizes ricochet risks. “The specially engineered materials were critical,” noted Professor Subramaniam. “They ensure strength and integrity under extreme conditions, setting a new standard for high-altitude construction.”
Project PRABAL exemplifies the power of academia-industry-defense collaboration, aligning with the “Make in India” initiative to foster indigenous innovation. Simpliforge Creations, founded in 2022, has been a trailblazer in additive construction, previously delivering India’s first 3D-printed bridge, the world’s first 3D-printed place of worship, and the Indian Army’s first in-situ 3D-printed medical facility. “This bunker is a milestone in our journey toward extraterrestrial applications,” said Hari Krishna Jeedipalli, MD of Simpliforge. “The insights from Ladakh validate our technology for remote terrains and even space habitats on the Moon and Mars.”
The Indian Army’s adoption of 3D printing reflects its commitment to modernizing infrastructure in challenging regions like Ladakh, where traditional construction is slow and resource-intensive. The bunker, which has cleared rigorous field trials, can be deployed in various configurations, from protective shelters to command posts, enhancing troop safety and operational efficiency. “This technology is a game-changer,” said a senior Army official. “It allows us to build durable infrastructure rapidly, even in the most inhospitable terrains.”
The 3D-printed bunker strengthens India’s defense preparedness along the LAC, where tensions with China have underscored the need for robust, quickly deployable infrastructure. Since the 2020 Galwan Valley clash, the Indian Army has scaled up habitat and storage facilities for 22,000 troops and 450 tanks in Ladakh. The PRABAL bunker, located near forward positions, complements these efforts by providing a cost-effective, sustainable solution that reduces construction time from weeks to days.
Globally, the project sets a benchmark, surpassing previous high-altitude 3D printing attempts. Its success could pave the way for commercial applications in remote civilian infrastructure, disaster relief, and border security. The Army plans to expand the technology’s use for additional bunkers, barracks, and medical facilities across Ladakh, Sikkim, and Arunachal Pradesh, further integrating it into its “Year of Technology Absorption 2024” initiative.
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