By Kamal Shah
Echoing the priorities laid down by Atmanirbharta, Bharat Dynamics Limited has made gigantic strides in the realm of hi-tech cutting-edge defence production. Its expertise in the modernization of weaponry has been globally acknowledged as has its reliance on increased indigenization. BDL Chairman and Managing Director, Commodore A Madhavarao (r) shares deep insight into the successes notched by the company under his stewardship and discusses future projects in rhythm with the demands of the nation’s forces.
Q. Within India’s defence industry, BDL has been an important player, notably in missile systems. When it comes to extending its present manufacturing capacities, what are the firm’s short-term ambitions, especially in light of the growing need for indigenous defence equipment as a result of the ‘Make in India’ initiative?
A. BDL’s Production strategy has been interwoven to achieve Atmanirbharta in defence production. In this direction, several measures have been taken.
Modernization. For instance, modernization of its production facilities has been done. Some of the facilities which BDL has taken up are.
- The Surface-Mount Technology & ‘High-Performance Computing facility’ at BDL, Kanchanbagh Unit have been commissioned.
- An environmental testing facility for large systems like complete Heavy Weight Torpedoes has been established at the Visakhapatnam Unit of the Company which is a first of its kind in the Country.
- A “Warhead” manufacturing facility has been set up at the Bhanur unit, with the capability and capacity to manufacture all warheads required for products being manufactured at BDL.
- State of art “Radio Frequency (RF) & Imaging Infra-Red (IIR) Seeker facilities” have been set up at Kanchanbagh Unit for the manufacture and testing of RF & IIR Seekers for SAMs and ATGMs
respectively. It is further extended to manufacture and testing of RF/IIR Seekers for all modern missiles.
Capacity Augmentation.
- For capacity augmentation of BDL Ibrahimpatnam Unit additional infrastructure for assembly and testing of larger missiles during the development as well as production phase has been taken up as in the second phase of the Infrastructure project. Further, High-Temperature Carbon Composites (HTCC) are being set up in this unit to realize Carbon and Silicon Carbide (C-SiC) composite products for advanced weapon systems. All the Future Missiles would be smart and compact, working at Supersonic speeds requiring high strength-to-weight ratio components capable of withstanding high temperatures. To meet these requirements, there is a need to produce special materials like CARBON FIBRE REINFORCED SILICON CARBICE MATRIX Composites (C/SiC) developed by ASL, RCI. Efforts are on by BDL to produce the same.
- The construction of a state of art propellant plant is in full swing in the UP defence corridor at Jhansi. Further, a manufacturing facility for the production of Grad Rockets will be set up in the same place.
- BDL has been constantly upgrading its manufacturing technologies and processes to state-of-the-art including industry 4.0 and robotics-operated workshops. Industry 4.0 has been implemented in one of the company’s facilities. It is being further extended to all the facilities of BDL.
Future Readiness.
- The following infrastructure projects are also being planned to be established in BDL.
- Hardware in Loop Simulation (HILS) for missiles, an essential test set up for the design of any missile. This facility is essential for BDL to foray into the design and development of new missiles.
- Metal and Non-Metal 3D printing, as additive manufacturing is a shot in the arm to improve timelines of manufacturing. These facilities also play a key role in developing prototypes whether it is for new designs or indigenisation.
- High Performance Computing facility for AI/ML, another key element in design aspects especially to reduce time and money in the development cycle of both new products and indigenization of sub-systems.
- Software Testing tools for Aerospace standards are critical with a quantum leap in the software part of any new weapon systems and with the element of AI and ML enhancing the software role significantly.
Indigenization. Indigenization is one of the major key focus areas, enabling BDL to mitigate its dependency on foreign OEMs and offer competitively priced products both for domestic and international customers. BDL has successfully achieved significant levels of indigenization for the “all-time import items” of the weapon systems being currently supplied to the Indian Army. BDL has effectively synergized the efforts of the large MSME echo system developed over the last five decades in the indigenization of various weapon systems and sub-systems and drastically reduced the dependency on foreign suppliers. BDL also regularly participates in various iDex Programs and has awarded 12 iDeX projects to Startups.
Optimization of Production Lines. BDL has incorporated “Flexible production lines” to easily adapt to the production of the latest generation missiles or to augment the capacity of production. Further, BDL recognizes the imperative to optimize its existing production lines to enhance efficiency and output. By streamlining processes and implementing cutting-edge technologies such as Industry 4.0, BDL aims to elevate its manufacturing capabilities, ensuring timely delivery of products with the highest quality. BDL has effectively enhanced its production facilities to double the existing production capacity and by optimal utilization of the existing resources BDL is fully geared up to deliver well beyond its rated capacity, to meet the requirements of the Nation.
Expansion Plans. BDL currently has manufacturing facilities located at Hyderabad, Bhanur, and Ibrahimpatnam, all three in Telangana State and the fourth one at Visakhapatnam in Andhra Pradesh. To cater to the growing demands of the Indian Armed Forces and friendly foreign Nations, BDL is setting up two more units – one at Jhansi in the UP – Defence Corridor and another one at Amravati in Maharashtra. Further land is being acquired for establishing a very large Plant for future requirements and also at Visakhapatnam for expansion of the Vizag Unit which manufactures underwater weapon systems.
Talent Acquisition. Human resource in terms of highly skilled manpower is the strength of BDL and a key factor in our capability to produce state of art weapon systems. BDL is recruiting fresh manpower from premier institutions of the country like IITs, NITs, IIITs etc and training them to leverage emerging technologies needed for manufacturing advanced generation of missiles and other niche technology products necessary for the Armed Forces.
Generating ‘synergy’ through Start-ups. The thrust being given to start-ups by the Government of India has enabled companies like BDL to synergize its “decades-long missile manufacturing expertise” with innovative ideas from young ‘start-ups’. BDL has actively engaged with various startups directly and has substantially invested in some of them directly apart from contributing through the various DDP/MoD/GoI initiatives like iDex, Srijan, PIL listing, etc.
Q. Can you offer any insight into the long-term vision that BDL has for helping India’s attempts to create an indigenous defence industry? To what extent does BDL want to boost India’s defence ecosystem over the next ten years by focussing on developing new technology or products?
A. The long-term vision of BDL is to make India self-reliant in Missiles and its allied products in a phased manner.
The main areas of focus are:
- Indigenous Development of all Critical Technologies pertaining to Missiles & Underwater Weapons like Seekers, Homing Systems, Avionics, Engines for Cruise Missile, Naval Ant-ship Missiles & UAVs, Ramjet motors, advanced guidance systems, and specialized warheads, Radio Frequency (RF) systems, Antenna Design & Electronic Warfare etc.
- Working on the development of
- Next Gen ATGMs,
- SAL Seeker ATGM,
- Drone-delivered missiles and Bombs,
- Weaponization of High endurance UAVs,
- High Energy Weapon System,
- Counter Drone System,
- Loitering Munition,
- Combat Autonomous Vehicles (Ground and Water),
- High Energy Propellants,
- Smart Bombs,
- Rockets & Smart Ammunition,
- Weapon Systems integration into Platforms,
- Small Satellite Launch Vehicle (SSLV) & Satellites for military & commercial usage,
- Scramjet, Hypersonic weapons etc.
- Acquiring and developing AI-driven systems and hypersonic weapons.
- Establishing partnerships with premier Indian institutes like the Indian Institutes of Technology (IITs), National Institutes of Technology (NITs), Indian Institute of Science (IISc), and other specialized research centres to foster innovation.
- Establish joint ventures with international defence firms to manufacture missile systems and components in India both for domestic and international requirements. These ventures will enhance BDL’s manufacturing capabilities, allow it to leverage global best practices and be part of the global supply chain for weapon systems.
- All foreign ToT projects are aimed at bridging the technology gaps and speeding up the bridging process. Further, these collaborations are for making inroads into the global defence market. In each of these cases, BDL is continuously striving to maximize the indigenous content. These elements are well entrenched right at the contractual stage itself.
Q. What strategies does BDL employ to change its product portfolio to maintain its competitive edge in the international arena in light of the fast advancement of defence technology, particularly in areas such as hypersonic weapons and AI-driven defence systems? I was wondering if there are any particular programs or collaborations that you might promote.
A. To maintain a competitive edge in the international market, especially in industries like defence where technological advancements such as hypersonic weapons and AI-driven systems are crucial, BDL typically adopts a range of strategic approaches. Here are Some of the strategies that BDL use to adjust their product portfolios are:
- Working closely with India’s premier Defence Research & Development Organization (DRDO). BDL has been continuously associated with DRDO in the design & production of various weapons and weapon systems for more than four decades. BDL is the prime Production Agency for some DRDO-developed future Weapon Systems such as Nag, Helina, Akash, MPATGM, QRSAM, Akash NG, Garuthma, Rudram, Pralay Under Water Weapon etc. BDL has been involved right from the development phase so as to absorb technology and has put in place the necessary resources for acquiring the state-of-the-art expertise in the Integration, Assembly & Testing of the above weapon systems along with their critical technology sub-systems like High-Resolution IIR Seekers and RF Seekers, advanced propellants, warheads etc. BDL is further planning to work with DRDO with High Energy Weapons, Supersonic Missiles etc.
- Investing in R&D and Innovation. BDL is progressively allocating significant resources to research and development in niche technologies, focusing on emerging technologies like Hypersonic systems, AI-based threat detection, autonomous systems, weaponization of Drones, anti-drone systems etc. This investment allows BDL to create cutting-edge products that can meet new requirements and anticipate future demands in the defence market.
- Strategic Partnerships and Alliances.
- To stay at the forefront of technological developments, BDL is partnering with Foreign OEMs, Research institutions, Start-Ups etc.
- Foreign OEMs.
- BDL has been Proactively working with Foreign OEMs and global Defence suppliers & signed Long-term MoUs with some of them to bring the latest technology Products to India & to indigenize the technology, in a progressive manner.
- Formation of JVs with some of the Global & Domestic defence manufacturers to manufacture a wide variety of the latest technology products for Domestic as well as export markets.
- Diversifying into precision component manufacturing for global supply chains
- Research Institutes & Start-ups.
- BDL has taken up technology collaboration with various prestigious Research institutions and start-ups to facilitate knowledge exchange, joint development, and access to new technologies faster than independent efforts.
- This is particularly effective when BDL needs to enhance capabilities in specialized areas like AI or advanced weapon systems.
- Diversification of Product Lines. By expanding into, technological innovations such as integrating AI into traditional defence platforms or developing dual-use technologies (civilian and military), BDL can broaden their product range as well as services to various customers. As part of diversification, BDL is working with FOEMs, with Start-Ups/MSMEs and In-house R&D on Rockets and Smart Ammunition UAVs/Loitering Munitions, Anti UAV Systems, Weapon Integrator on Platforms (Aircraft, UAVs and Ships), SSLV and Satellites, future technologies like High Energy Weapons, Scramjet, Hypersonic Missile. BDL has been shortlisted for RFP by InSpace for the Small Satellite Launch Vehicle (SSLVs) and satellites. This diversification allows BDL to adapt to changes in demand and maintain relevance as the market evolves. BDL has initiated various actions concerning setting up a facility for the manufacture of Small Turbo Fan Engines (STFE) for various missiles and loitering munition requirements. BDL is in talks with both DRDO and FOEMs for the same.
- Trend Analysis. BDL is continuously analyzing the market and Monitoring trends in the international defence market and focusing on customizing its products to meet the specific needs of the domestic as well as international market.
- Developing Dual-Use Technologies. BDL is focusing on technologies that have both military and civilian applications that can help companies mitigate risks associated with fluctuations in defence budgets.
Q. Given the recent geopolitical shifts and the increasing emphasis on enhancing India’s border security, what role do you anticipate BDL will have in reinforcing the nation’s short-term defence readiness? Are there particular products or initiatives designed to improve this capability?
A. BDL being the lead weapon system manufacturer and complete Life Cycle Support provider to the Indian Armed Forces and now to the growing number of Friendly Foreign Countries (FFCs) is expected to play a crucial role in enhancing India’s defence capabilities in light of recent geopolitical shifts and the increased focus on border security.
BDL is a key manufacturer of defence equipment, especially in the domain of missile systems and weapon systems, which are critical for reinforcing India’s short-term and long-term defence readiness. The long association with FOEMs in the Indigenous manufacture of missiles and weapon systems and the Integrated Guided Missile Development Programme (IGMDP) has already given BDL a solid foundation to support the Indian armed forces with a range of guided missile systems.
BDL’s Surface-to-Air Missile system is designed to intercept enemy aircraft and UAVs. With a range of 25 km and an advanced targeting system, this system is a significant tool for India’s air defence, providing rapid-response capabilities in the event of aerial threats. Various SAMs are being added to this arsenal.
Similarly, BDL is the manufacturer of various ATGMs which are crucial in border defence, especially in terrain-sensitive areas. These missiles provide effective deterrence against hostile tank movements.
BDL plays a pivotal role in bolstering India’s defence capabilities through the production of advanced weaponry, particularly with indigenously designed Astra, Beyond-Visual-Range Air-to-Air Missile (BVRAAM). This technology equips the Indian Air Force and Indian Navy with the critical ability to engage enemy aircraft at significant distances, enhancing aerial combat effectiveness and strategic deterrence.
In addition, BDL’s manufacturing portfolio includes torpedoes and various underwater weapons, thereby ensuring a comprehensive multi-front defence posture. This capability is increasingly vital given the evolving regional maritime threats that India faces. By diversifying its production capabilities, BDL contributes to a robust national security framework that addresses both aerial and naval challenges.
Aligning with the Indian government’s initiative for defence indigenization, BDL aims to reduce reliance on imports while enhancing domestic production capabilities. This strategic shift is essential for the rapid scaling of manufacturing processes for critical defence systems, thereby reinforcing India’s defence preparedness in the short term. The emphasis on self-reliance not only strengthens national security but also promotes economic growth through local manufacturing.
BDL has also engaged in partnerships with global defence companies for technology transfer agreements, facilitating the production of advanced missile subsystems within India. Such collaborations ensure access to cutting-edge technology, enabling BDL to remain competitive in the global defence landscape. This approach not only enhances the quality and sophistication of India’s defence arsenal but also fosters innovation within the domestic industry.
Furthermore, BDL is investing significantly in Research and Development (R&D) to expand its product line with next-generation missile systems. The focus on upgrading existing platforms and developing multi-role missiles is crucial for enhancing defence agility and responsiveness to emerging threats. In today’s complex warfare environment, the ability to adapt and innovate is paramount.
In response to contemporary challenges, BDL is also exploring the development of drone-delivered weapons and anti-drone systems, particularly in the realm of hard-kill solutions. The integration of such technologies is vital in modern warfare, where unmanned systems increasingly play a critical role in combat scenarios.
Finally, BDL’s expertise in logistics management and its robust production capacity enables the rapid supply of defence materials. This capability is particularly important for border deployments, where quick response times are essential for maintaining operational readiness and safeguarding national interests.
BDL’s focus on missile systems, indigenous production, and strategic R&D aligns seamlessly with India’s immediate defence needs. By fostering self-reliance and innovation, BDL not only enhances the operational capabilities of the Indian Armed Forces but also contributes to the broader goal of establishing a resilient and secure national defence infrastructure.
Q. BDL possesses a strong export portfolio. Can you provide a detailed explanation of the company’s approach to increasing its presence in international markets in the upcoming period? What strategies does BDL employ to manage its domestic obligations in conjunction with its global pursuits?
A. BDL epitomizes innovation and self-reliance in the defence sector, offering state-of-the-art products designed indigenously and competitively priced, with minimum dependence on foreign Original Equipment Manufacturers (OEMs). This independence not only enhances national security but also positions BDL favourably in the global defence market.
Recognizing the potential for expanding its footprint internationally, BDL has placed a substantial emphasis on the export of weapon systems. The establishment of an export cell within the Business Development Division marks a strategic initiative aimed at exploring diverse markets and pursuing export opportunities. This cell is fundamentally tasked with preparing country-specific strategies to identify and promote BDL’s products, ensuring that exports are aligned with the requirements of various regions.
To facilitate the promotion of its exportable products, BDL has appointed Channel Partners and agents in several countries. These partnerships are critical as they enable BDL to navigate local markets effectively while increasing visibility among potential clients. Furthermore, BDL actively participates in foreign defence exhibitions, which serve as platforms for showcasing its advanced capabilities, and products, and forging meaningful connections with representatives from foreign armed forces and ministries of defence.
In bolstering its international engagement, BDL is collaborating closely with Indian Embassies and Defence Attaches to organize meetings and visits with foreign stakeholders. This proactive approach not only fosters better relationships but also enhances the visibility of BDL’s offerings on a global scale. Additionally, plans for establishing representative offices in strategic foreign locations further illustrate BDL’s commitment to strengthening its international presence and engagement.
Competitive bidding is another avenue through which BDL demonstrates its resolve to rival global manufacturers and suppliers. The company’s ability to respond effectively to leads from Friendly Foreign Countries for advanced systems such as Surface-to-Air Missiles (SAMs), Anti-Tank Guided Missiles (ATGMs), Air-to-Air Missiles, and other sophisticated weaponry highlights its competitive edge. The export cell’s active pursuit of these leads, coupled with ongoing interactions with overseas customers, is instrumental in achieving BDL’s export targets.
Such efforts have already yielded tangible results, with orders secured for the export of various products, including Light Weight Torpedoes, Counter Measures Dispensing Systems, and the Akash Weapon System. These successes not only underscore BDL’s potential in the international market but also reflect the growing confidence in its indigenously developed defence capabilities.
BDL’s strategic initiatives geared towards enhancing its export capabilities reinforce its position as a leading player in the defence sector. By capitalizing on indigenous design and manufacturing strengths, actively engaging in global markets, and pursuing competitive opportunities, BDL is well on its way to establishing a robust presence in the international arena while contributing to India’s defence export landscape.
Q. What strategies will be employed to effectively demonstrate the capabilities of the integrated underwater suite at the Euro Naval exhibition?
A. The development of underwater weapon systems has become a focal point in modern naval warfare, reflecting a significant evolution in defence technology. This essay outlines the current advancements in this domain, particularly focusing on lightweight and heavyweight torpedoes, unmanned underwater vehicles (UUVs), decoy systems, and sonobuoys.
At the forefront of our offerings is the lightweight torpedo, a versatile product suitable for deployment from both small and large naval vessels, including Helicopters. This system is already available for export, showcasing its operational flexibility. Additionally, we have successfully supplied heavyweight torpedoes to the Indian Navy, with indications of potential repeat orders, emphasizing the reliability and effectiveness of our products. Currently, the new version of lightweight and heavyweight torpedoes are undergoing advanced trial stages, paving the way for their future export.
In parallel, we are actively developing unmanned underwater vehicles, which are also in the trial phase. These UUVs represent a significant leap in underwater reconnaissance and combat capabilities. Furthermore, we are innovating decoy systems designed to counter underwater threats, including collaborations with established Western Original Equipment Manufacturers (OEMs) to create advanced torpedo destroyers, colloquially known as “Torbusters”. Our mobile target emulators are also being developed to enhance training and operational readiness.
Our commitment to providing comprehensive underwater solutions is evident in our ongoing work with sonobuoys—consumable devices crucial for naval forces to maintain an accurate underwater picture. Collaborating with the Defence Research and Development Organisation (DRDO) and other institutions, we are progressing toward the indigenous development of these systems. Notably, we have established a Memorandum of Understanding with Ultra USA to supply specialized sonobuoys for the P-8I aircraft, further enhancing our capabilities in this area.
As we prepare to showcase our advancements at the forthcoming Euro Naval exhibition, we aim to highlight our complete underwater suite, which integrates sonar systems, launchers, and weaponry. This collaborative approach, involving key industry players such as L&T and Mahindra, ensures that we deliver a cohesive and effective defence solution.
Our extensive portfolio of underwater weapon systems reflects our dedication to advancing naval defence capabilities. Through ongoing trials, collaborations, and innovations, we are poised to meet the demands of both the Indian Armed Forces and the global market, ensuring that our products remain competitive and effective in contemporary warfare