Indian deep-tech company Simpliforge Creations, in collaboration with the Indian Institute of Technology (IIT) Hyderabad and the Indian Army, has completed India’s first on-site 3D printed military-grade protective structure. Built at an altitude of 11,000 feet in Leh under Project PRABAL, the bunker structure is hailed as a technical milestone—claimed by the team to be the world’s highest-altitude 3D printed structure built under high-altitude, low-oxygen (HALO) conditions.
Arun Krishnan, Indian Army representative and PhD scholar at IIT Hyderabad, explained the project’s origin. “Several teams and companies had attempted to bring 3D printed construction to the high-altitude terrain of Leh, but the extreme conditions of Ladakh proved to be a formidable challenge. It was the unmatched synergy between Simpliforge Creations and IIT Hyderabad that finally made it possible. Their technical depth, adaptability, and relentless focus on innovation enabled the successful execution of Project PRABAL. Together, we didn’t just build a structure—we proved that indigenous, cutting-edge technology can overcome even the harshest operational environments and deliver tangible impact for our armed forces.”
Engineering in Extreme Environments
Project PRABAL involved deploying a customized robotic 3D printing system designed to operate in high-altitude terrain with minimal oxygen and temperature fluctuations. The bunker was form-optimized for strength and built using locally sourced materials. The 3D printing process took approximately 14 hours, with the entire project completed in five days.
Simpliforge Creations CEO, Dhruv Gandhi, discussed the operational challenges. “Executing this project in the high-altitude, low-oxygen environment of Ladakh was an immense challenge—for both our team and our machines.” He explained that the reduced oxygen levels affected various aspects, including the performance of power systems, which produced less energy than usual, and human efficiency. The combination of low humidity and high UV exposure also posed significant challenges to the material’s integrity.
Prof. KVL Subramaniam of IIT Hyderabad emphasized that working in such extreme conditions required not only structural innovation but also advanced material science. In collaboration with Simpliforge Creations, IIT Hyderabad developed a concrete mix capable of being 3D printed on-site, ensuring superior mechanical performance, durability, and resilience. The team conducted rigorous testing on locally sourced materials to optimize the mix design, ensuring it could withstand environmental stresses.
Hari Krishna Jeedipalli, Managing Director at Simpliforge, noted that this project builds on the company’s previous additive construction achievements, including India’s first 3D printed bridge and the world’s first 3D printed place of worship. “Each project has been a leap forward, and this bunker in Ladakh marks a crucial milestone in our journey towards extra-terrestrial applications,” he said. “Looking ahead, we envision commercializing this technology for remote terrain applications, and extending its use beyond Earth—towards space habitats on the Moon and Mars.”
Global Developments in On-Site Defense Manufacturing
India’s progress with Project PRABAL aligns with a global shift toward mobile, on-demand manufacturing technologies in defense. In the US, Project Convergence–Capstone 5 (PC-C5) saw Firestorm demonstrate its mobile 3D printing platform for rapid fabrication and repair. The xCell system produced drone platforms for Lockheed Martin and restored a downed drone in 72 hours using printed parts.
Similarly, Australian manufacturer SPEE3D showcased its Expeditionary Manufacturing Unit (EMU) during the U.S. Department of Defense’s Point of Need Challenge (PONC). The metal 3D printer operated effectively in sub-zero temperatures, producing durable metal components on-site—addressing key logistical challenges in remote or austere environments.
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Featured image shows 3D printed protective military structure. Photo via Simpliforge Creations.
