In a global first, Simpliforge Creations, in partnership with IIT Hyderabad and the Indian Army, has completed the world’s highest on-site 3D printed military structure under Project PRABAL. Located at 11,000 ft in Leh, this groundbreaking bunker was printed under extreme high-altitude, low-oxygen (HALO) conditions—demonstrating India’s prowess in deep-tech and defense innovation.
The project was led by Arun Krishnan, a PhD student at IIT-Hyderabad, with technical mentorship from Prof. K.V.L. Subramaniam. Using locally sourced materials and a specially designed concrete mix, the structure was printed in just 14 hours, with the entire project completed within 5 days.
Key innovations included:
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A custom-developed 3D concrete mix engineered for high-altitude performance
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Robust robotic printing systems set up within 24 hours
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Overcoming challenges like low oxygen, high UV exposure, and harsh thermal variation
Dhruv Gandhi, CEO of Simpliforge, emphasized the operational challenges:
“Even the power systems delivered lower energy at altitude. But we proved rapid deployment is possible, with a strong structure delivered on schedule.”
Prof. Subramaniam added,
“We had to tailor material science to extreme climates, conducting deep studies on local aggregates and mix rheology.”
This military-grade 3D printed structure—India’s first of its kind—has passed rigorous field trials and paves the way for rapid deployable infrastructure in the toughest terrains.
Hari Krishna Jeedipalli, MD of Simpliforge, highlighted the project’s broader vision:
“From India’s first 3D printed bridge to space-ready construction, this project in Ladakh is a stepping stone to extra-terrestrial habitats on the Moon and Mars.”
