IIT-Hyderabad sets a world record by building the highest 3D-printed military bunker at 11,000ft in Leh, revolutionizing defence infrastructure in high altitudes.
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| India builds the world’s highest on-site 3D-printed military bunker in Leh through IIT-Hyderabad and Simpliforge, marking a major defence tech milestone. Image Courtesy: TOI |
Hyderabad, India – April 19, 2025:
In a record-setting achievement that blends cutting-edge innovation with strategic defence needs, the Indian Institute of Technology Hyderabad (IIT-H), in collaboration with Hyderabad-based Simpliforge Creations and the Indian Army, has successfully constructed the world’s highest on-site 3D-printed military bunker at an altitude of 11,000 feet in Leh, Ladakh.
According to a ToI report, the bunker, completed in just five days with a total 3D printing time of 14 hours, stands as a landmark in high-altitude construction technology. It is not only the highest in-situ 3D-printed structure globally but also India’s first on-site 3D-printed protective military shelter, developed under the Project Prabal initiative—highlighting indigenous R&D and a strong academia-industry-defence partnership.
Constructed using locally sourced materials, the project was led by Prof. KVL Subramaniam of IIT-H, in association with Arun Krishnan, a serving officer from the Indian Army currently pursuing his PhD at the institute. The mission was carried out under extreme High Altitude and Low Oxygen (HALO) conditions, posing challenges for both human performance and machinery.
Prof. Subramaniam underscored the critical role of material science innovation. “Developing a concrete mix that could withstand low humidity, wide temperature swings, and reduced oxygen was essential. Working with Simpliforge Creations, we created a high-performance mix that not only supported on-site 3D printing but also delivered exceptional strength and durability,” he said.
The custom material underwent rigorous environmental stress testing at IIT-H before being transported to Leh. These simulations were crucial to adapt the technology for high-altitude field conditions.
Dhruv Gandhi, CEO of Simpliforge Creations, detailed the operational hurdles. “The low-oxygen environment impacted everything from energy output to human efficiency. The robotic 3D printer system had to be set up and calibrated in under 24 hours, despite extreme weather and UV radiation. Our team overcame all obstacles to prove the resilience and scalability of this technology.”
This first-of-its-kind deployment is expected to dramatically reduce the time and cost involved in constructing essential military infrastructure in remote and inhospitable terrains. According to IIT-H, the success of this project opens up opportunities for rapid, sustainable construction of bunkers, shelters, and other critical installations in high-altitude regions.
The initiative also aligns with India’s push for self-reliance in defence technology, showcasing how academic research and private innovation can work together to meet strategic national needs.
“This breakthrough strengthens India's position in the global defence technology landscape,” said one senior defence official. “The ability to rapidly deploy strong, durable infrastructure at high altitudes could be a game-changer for our armed forces.”
With the successful execution of this 3D-printed bunker, IIT-Hyderabad and its partners have not only made engineering history but also laid the foundation for future innovations in extreme environment construction.