In a groundbreaking achievement, Indian deeptech firm Simpliforge Creations, in partnership with IIT Hyderabad and the Indian Army, has constructed the world’s highest on-site 3D printed structure at 11,000 feet in Ladakh under Project PRABAL. This protective bunker was printed in just 14 hours using a specially engineered concrete mix designed for high-altitude, low-oxygen conditions.
This feat, supported by the Indian Army and spearheaded by Arun Krishnan—a PhD student at IIT Hyderabad and a defence professional—marks the highest-ever 3d-printed construction executed in high-altitude, low-oxygen (HALO) conditions.
The structure was completed using a specialized robotic 3D printing system capable of operating in sub-zero temperatures, low humidity, and UV-intense environments. Developed in close coordination with IIT Hyderabad under the guidance of Prof. K.V.L. Subramaniam, the project required the formulation of custom materials and novel engineering approaches to adapt to the severe climate.
“Executing this project in the high-altitude environment of Ladakh was an immense operational challenge,” said Dhruv Gandhi, CEO of Simpliforge Creations. “The reduced oxygen levels impacted everything—from energy output to human performance. Despite that, our team set up the robotic printer system within 24 hours and completed the structure in a record five days,” he added.
Project PRABAL has showcased India’s ability to innovate in difficult terrains and underscored the potential of academia-industry-defence collaboration in delivering indigenous technology solutions. The structure has since undergone and cleared rigorous field trials.
For Arun Krishnan, the project is personal. “PRABAL was conceptualized during my M.Tech at IIT Hyderabad. Multiple teams had tried to implement 3D printing in Ladakh, but the environmental challenges were too daunting. It was the synergy between IIT-H and Simpliforge that made it possible. We didn’t just build a bunker—we demonstrated that Make-in-India technology can deliver where global solutions falter.”
Simpliforge’s success adds to its pioneering portfolio—including India’s first 3D printed bridge and medical facility—while also offering a testbed for future extra-terrestrial construction. This milestone highlights India’s growing capabilities in defence tech, additive manufacturing, and strategic infrastructure innovation.
This milestone highlights India’s growing capabilities in defence tech, additive manufacturing, and strategic infrastructure innovation.
Team BharatShakti
