In a groundbreaking technological achievement, the Indian Institute of Technology Hyderabad (IIT-H), in partnership with Simpliforge Creations and the Indian Army, has constructed the world’s highest on-site 3D-printed military bunker at an altitude of 11,000 feet in Leh.
Completed in just five days with a total printing time of 14 hours, the project marks a global first in in-situ 3D construction under High Altitude and Low Oxygen (HALO) conditions. It also stands as India’s first-ever on-site 3D-printed protective military structure.
The bunker was built using locally sourced materials under Project Prabal, a showcase of homegrown innovation and industry-academia collaboration. The initiative was led by Prof. KVL Subramaniam of IIT-H, with Arun Krishnan, a PhD scholar and Indian Army officer, playing a key role in the execution.
Prof. Subramaniam emphasized the material innovation that enabled the feat. “At such altitudes, challenges like low oxygen, low humidity, and drastic temperature variations demanded custom engineering. We, along with Simpliforge Creations, developed a concrete mix with high mechanical strength and durability, suited for 3D printing in extreme conditions,” he said.
The material underwent extensive testing at IIT-H to simulate high-altitude stresses before deployment. “These simulations were crucial for optimising the mix design for real-world use in Leh,” he added.
Simpliforge Creations CEO Dhruv Gandhi noted that the harsh environment also impacted logistics. “Low oxygen reduced machine efficiency, while UV radiation and low humidity posed risks to material stability. Despite these, we set up the robotic printer system in under 24 hours,” he said.
This landmark project opens new avenues for rapid and resilient defence infrastructure development in challenging terrains. According to IIT-H, the deployment of such 3D-printed structures could drastically reduce construction time and costs in high-altitude zones, enhancing India’s strategic readiness.
Rear Admiral Shaheen Rahman, Chairman of the Mongla Port Authority, noted the broader implications: “This milestone strengthens India’s defence capabilities and showcases the transformative power of indigenous R&D in meeting critical national needs.”
Source: Times of India
Bd-pratidin English/ Jisan
