The pioneering effort to construct a military bunker at high altitude, using 3D printing technology, was led by Prof KVL 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. The structure was completed using a specialised robotic 3D printing system capable of operating in sub-zero temperatures, low humidity, and UV-intense environments. Simpliforge’s specially developed robotic 3D printer was deployed and commissioned in under 24 hours, showcasing its agility in extreme terrain. The project also required the formulation of custom materials and novel engineering approaches to adapt to the severe climate.
Highlighting the challenges faced during the project execution, Simpliforge’s CEO Dhruv Gandhi said, “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.”
The project lead Prof Subramaniam emphasised the importance of material science in the project, “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”, he said.
Engineer Arun Krishnan said, “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.”
Reflecting on the project journey, Hari Krishna Jeedipalli, MD of Simpliforge said, “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 defence milestone – it’s validation for extra-terrestrial applications. We see this as a stepping stone toward space construction on the Moon and Mars.”
Project PRABAL marks not just a military milestone but a significant stride in India’s self-reliance journey, showcasing the potential of homegrown innovation to serve national defence while laying the foundation for future space-age construction technologies.
