From R&D to Reality: How our Hyderabad Plant redefines manufacturing

"Dream, dream, dream! Dreams transform into thoughts and thoughts that result in action." - Dr. A.P.J. Abdul Kalam

...And then we dreamt. We didn't just want to be another name in the industry; we wanted to be the ones who defined it. For years, we’ve held the vision of a genuinely self-sufficient India, a country that doesn’t merely import excellence, but builds it from the foundation. We understood that to genuinely shape the future, we needed to create it ourselves, with the determination and accuracy that this heritage warrants.

Technology innovation is the real catalyst to human progress

From the stone at age to today’s hyper-connected AI world, every era is defined by innovation in technology. In the power systems industry, technology is definitely about the hardware, but the software and control logic is also becoming equally important for optimal functioning. Exicom’s R&D focuses on optimizing power density and conversion efficiency. With an amazingly talented team of over 280 engineers, we combine advanced materials with intelligent control software. We maximize power output within smaller footprints while protecting the local electrical infrastructure.

But as any engineer will tell you, a brilliant design is only half the battle. You can have the most sophisticated simulation in the world, but it doesn't mean a thing if it can't survive the transition from a lab bench to a massive production line. We knew that to truly change the industry, we had to find a way to take that 'lab genius' and scale it without losing a single drop in its integrity.

Innovation is fully realized only when manufacturing scales

A brilliant invention only changes the world if we can mass-produce it perfectly. In 1785, Honoré Blanc proved that if you manufacture gun parts to be the same size, you can quickly assemble them without needing an artisan to custom-fit every single piece. In 1851, Joseph Whitworth invented tools that could measure down to a millionth of an inch. This guaranteed that standardized parts would always fit together perfectly. Henry Ford later combined these perfectly standardized parts with a moving assembly line to build products incredibly fast. Today, we use automated smart factories and advanced scanners instead of hand tools, but the fundamental goal is the same: making highly complex technology (like modern electronics) with perfect accuracy, millions of times over.

But now with global supply chains being complicated and fragile, the method of scaling is as important as the scale itself.

However, proprietary manufacturing is required for best usage of technology

History has taught us that a great idea only truly 'arrives' when you can manufacture it perfectly, millions of times over. For Exicom, scaling isn't just about making things bigger; it’s about building a physical home for our innovation where we control every single variable. To get the most out of technology and keep the original design intact, proprietary manufacturing is an absolute necessity.

For Exicom, controlling their proprietary is crucial. We design, engineer, and manufacture 95% of the rectifiers in-house. They write their software design, their own Battery Management Systems, and make their own precision mechanical enclosures. This way we ensure that the great ideas from the lab are not watered down or compromised by companies.

A brilliant invention only changes the world if we can mass-produce it perfectly. In 1785, Honoré Blanc proved that if you manufacture gun parts to be the same size, you can quickly assemble them without needing an artisan to custom-fit every single piece. In 1851, Joseph Whitworth invented tools that could measure down to a millionth of an inch. This guaranteed that standardized parts would always fit together perfectly. Henry Ford later combined these perfectly standardized parts with a moving assembly line to build products incredibly fast. Today, we use automated smart factories and advanced scanners instead of hand tools, but the fundamental goal is the same: making highly complex technology (like modern electronics) with perfect accuracy, millions of times over.

Having control over the process prevents problems that can happen when many different companies are involved. When the engineers who design a high-power EV charging module can talk directly to the technicians who put it together they can fix problems away. This control allows us to make high-quality products quickly and reliably without compromising the design.

Our approach is like a version of precision manufacturing. By having control, over production we can make a lot of high-quality products quickly and reliably without sacrificing the integrity of the original design. This level of control doesn't just give us quality; it gives us the resilience to build for the specific challenges of the Indian landscape.

Localization builds resilience across global supply chains

In a world of fragile global supply chains, "making it here" is our ultimate competitive advantage. For us, localization isn't just about cutting costs, it's about building tech that actually works in our 50°C summers. By designing and producing every single PCBA (the "brain" of the charger) right here in our own facility, we are bringing the future of global innovation to India..

Every PCBA utilized in Exicom's rectifiers, system controllers, AC chargers, and DC chargers is designed and produced in-house at our facility. Owning the intellectual property from start to finish means our R&D engineers and factory teams work as a single unit.  

Second, building locally gives us serious resilience. By manufacturing these complex components here in India, we aren't at the mercy of international shipping bottlenecks or sudden semiconductor shortages. We can consistently deliver what our telecom and EV partners need, even when the global market gets unpredictable.

But here is the most exciting part: we aren't just localizing older tech. We are actively bringing the next generation of global innovation directly to the market. When we acquired Tritium, a global leader in DC fast-charging, we set out to build India’s first facility dedicated entirely to liquid-cooled power modules.

If you look at traditional air-cooled chargers, they really struggle in our harsh 50°C summers. The internal fans just can't push enough hot air out, which leads to overheating, slowed charging speeds, and dust damage. Liquid cooling fixes all of that. By using a closed-loop fluid system, it pulls heat up to 1,000 times more efficiently than air. The result? Chargers that run perfectly at peak temperatures, take up much less space, and operate almost silently.

By building this proprietary, liquid-cooled technology locally, we’re able to roll out highly advanced systems like our scalable TRI-FLEX platform and our AI-driven Harmony chargers. For us, it’s not just about bulletproofing our supply chain; it’s about setting the standard for the future of heat-resilient, hyper-fast EV infrastructure.  

But to build something this advanced, we needed more than just a factory.

The Hyderabad Plant is where our R&D met reality

We believe that futuristic R&D requires a physical environment that can breathe life into complex theories. Our newly inaugurated manufacturing facility in Hyderabad is the physical culmination of this vision. It represents the exact geographical point where our boldest engineering concepts meet operational reality.

“Beautifully engineered. Masterfully manufactured.”

The selection of Hyderabad was highly strategic; the city offers a central geographical location, excellent connectivity with proximity to a major international airport, and an environment where government approvals and industrial support operate smoothly. With an investment of approximately INR 200 Crore, the campus is a sprawling 18-acre facility featuring a total built-up area of 2.8 Lakh square feet, of which 1.3 Lakh square feet is strictly dedicated to advanced electronics and electrical production.

To properly contextualize this scale, our Hyderabad facility operates at a magnitude exponentially larger than legacy plants, effectively acting as a platform capable of being up to 10x larger than the existing Gurgaon facility. At full operational capacity, the plant is designed to manufacture up to 300,000 chargers, massive volumes of rectifiers, and thousands of DC fast chargers. The facility is built strictly upon an advanced power electronics manufacturing platform equipped with Industry 4.0 digitally connected systems. It is a smart factory where cyber-physical systems communicate in real-time, ensuring that production metrics, quality checks, and material flows are continuously monitored and dynamically controlled.

Furthermore, the facility is a paragon of sustainable industrial design, constructed based on Indian Green Building Council (IGBC) norms. It features a 1000kW (1MW) rooftop solar capacity, extensive rainwater harvesting infrastructure, natural lighting optimization, and 40% green cover.

The care for technology cultivated in the R&D labs translates directly to the assembly line through a series of highly specific, automated, and precision-driven processes across multiple dedicated production zones:

The extreme precision of the SMT lines is a critical highlight. Operating with an accuracy of ±30 microns is vital because even microscopic misalignments during component placement can cause open circuits or insufficient pad overlap, leading to eventual failure under thermal stress. Furthermore, the deployment of 3D Solder Paste Inspection (SPI) is revolutionary. Since 60-70% of SMT defects originate at the solder paste printing level, the 3D SPI system evaluates not just the area, but the exact volume of microscopic solder joints. By validating the volumetric integrity of the paste before components are placed, the system actively prevents latent field failures that would otherwise only appear months after deployment.

Similarly, the use of Vision Camera Validation across the assembly lines transforms production from being highly skill-dependent to being flawlessly system-dependent. These optical AI systems continuously monitor the work-in-progress, eliminating human error by preventing incorrect cable routing, identifying missing connectors, and ensuring absolute adherence to the digital work instructions displayed at every station.

We have set our processes across 4 pillars to ensure quality

How do we ensure every product actually lives up to our "Beautifully Engineered" standard? At our Hyderabad plant, we don't leave it by chance. We built our operations around four core pillars:

1. Precision: Quality starts at the microscopic level. By using strict cleanrooms and incredibly precise placement technology, we ensure our foundational electronics are practically flawless. Catching tiny variations early prevents major performance failures down the road.

2. Automation & Control: We use robotics and automated vehicles to handle heavy, repetitive tasks. At the same time, AI vision cameras act as an unblinking extra set of eyes, instantly catching deviations and ensuring every single unit is built exactly the same way.

3. Testing & Validation: We don't trust a product until we've pushed it past its limits. Before anything leaves the factory, it goes through rigorous thermal, optical, and real-world stress tests. We even aggressively test supplier components before they are allowed onto our assembly line.

4. Traceability: Every unit we build gets a complete "digital twin." We track the exact torque applied to specific screws, log the exact batch of components used, and record the data at every station. If an issue ever arises in the field, we can trace it back to the exact root cause in seconds.

Ultimately, true global tech leadership isn't just about designing something brilliant in a lab; it's about building it flawlessly on the factory floor.

Over our next four updates, we are going to break down each of these pillars in detail. We'll show you exactly how our high-tech assembly lines take visionary designs and turn them into the resilient energy infrastructure the world needs.

The Hyderabad facility is a blueprint for the future of power electronics.  

We’ve set the benchmark. Now, we’re ready to lead the charge.