India's Simpliforge sets global record with world's highest on-site 3D printed structure in the Himalayas

In a groundbreaking achievement, Simpliforge Creations and IIT Hyderabad, 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 specially developed robotic 3D printer was deployed and commissioned in under 24 hours, showcasing its agility in extreme terrain. CEO Dhruv Gandhi highlighted the challenges: “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.”

“Operating at high altitudes with thermal extremes required specially engineered concrete,” says Prof. K.V.L. Subramaniam of IIT-Hyderabad. “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.”

“Project PRABAL began during my M.Tech journey. Previous attempts to bring 3D construction to Ladakh faltered due to harsh conditions,” says Arun Krishnan—PhD scholar at IIT Hyderabad. “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.”

“From India's first 3D printed bridge to the Army's medical facility, each project has advanced the frontier,” says Hari Krishna Jeedipalli, MD of Simpliforge. “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.”

This landmark project reaffirms India's deeptech leadership, combining innovation, defense utility, and the Make-in-India vision to pioneer future-ready infrastructure.