Simpliforge Creations, an Indian 3D construction printing company, and IIT Hyderabad, in collaboration with the Indian Army under Project PRABAL, have successfully completed the world’s highest on-site 3D printed military structure at 11,000 feet, in Leh. This milestone marks the first-ever protective military bunker built in high-altitude, low-oxygen (HALO) conditions using in-situ 3D construction printing.
The effort was led by Prof. K.V.L. Subramaniam of IIT-Hyderabad, Arun Krishnan, PhD scholar at IIT Hyderabad, and a multidisciplinary team. The structure, printed in just 14 hours using locally sourced materials, demonstrates how indigenous technology can deliver infrastructure rapidly and sustainably.
Simpliforge’s robotic 3D printer was deployed and commissioned in under 24 hours, showcasing its agility in extreme terrain. “Reduced oxygen levels impaired power efficiency and human performance. Low humidity and high UV radiation impacted material integrity – but our systems delivered a robust structure in just 5 days,” said Dhruv Gandhi, CEO of Simpliforge Creations.
Manufacturing on Demand
“Operating at high altitudes with thermal extremes required specially engineered concrete. Our team rigorously tested and optimized a mix suited to local aggregates and environmental stresses. This innovation was key to ensuring structural strength and durability,” said Prof. Subramaniam.
“Project PRABAL began during my M.Tech journey. Previous attempts to bring 3D construction to Ladakh faltered due to harsh conditions. It was the synergy between IIT Hyderabad and Simpliforge that finally overcame these barriers. We’ve proven that homegrown technology can thrive even in the toughest environments,” said Arun Krishnan.
“From India’s first 3D printed bridge to the Army’s medical facility, each project has advanced the frontier. This Ladakh bunker is more than a defense milestone – it’s validation for extra-terrestrial applications. We see this as a stepping stone toward space construction on the Moon and Mars,” said Hari Krishna Jeedipalli, MD of Simpliforge.
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Author: Edward Wakefield
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