Project No. 06 — Electric vehicle

Navya

Electric cargo three-wheeler.

In market Astro Motors 2020 — 2023 Role — Co-Founder

Navya. Astro Motors, 2020 — 2023.

Astro Motors incorporated in February 2020 to design a hatchback EV for the Indian market, then pivoted to a three-wheel cargo vehicle four months later. Navya is what came out of that pivot: a vehicle designed for manufacture without heavy investment in tooling, taken from a local fabricator's shed to ICAT certification.

Outcome. ICAT-certified and RTO registered as a cargo three-wheeler in November 2023. Astro Motors is manufacturing at scale, with a patent filed on a multi-gear manual transmission for EV.

Gallery

32 figures

**Fig. 01.** Early concept block — the hatchback thinking that preceded the pivot.

**Fig. 02.** Package sketches working out the cargo proportions.

**Fig. 03.** Space frame in CAD, with the leaf spring suspension called out.

**Fig. 04.** Manufacturing-led form after the tooling decision.

**Fig. 05.** Line-up study across the range.

**Fig. 06.** The first prototype going together at a local fabricator with a Chinese powertrain.

**Fig. 07.** Rolling chassis on the road outside the shed.

**Fig. 08.** Sheet metal folded by hand — the metal origami moment that changed how the vehicle was drawn.

**Fig. 09.** First proto was L3. The next was L5 — larger, with independent suspensions and Indian powertrains.

**Fig. 10.** Cabin panel out of the press.

**Fig. 11.** Tooling for the pressed parts.

**Fig. 12.** Pilot batch in the assembly bay.

**Fig. 13.** Loaded and driven — the cargo bed doing its job.

**Fig. 15.** Cab in bare metal before paint.

**Fig. 18.** Dashboard sketches, working the switch layout and instrument aperture.

**Fig. 19.** Dashboard sheet metal mock-up before the FRP prototype.

**Fig. 20.** Speedometer 3D print mock-up — aluminium casing, vacuum-cast prototype.

**Fig. 21.** The instrument cluster in hand.

**Fig. 22.** Dashboard fitted in the cab.

**Fig. 23.** Headlight housing drawn for the FRP mould.

**Fig. 24.** 3D printing plus sheet metal mock-up used to create the FRP mould.

**Fig. 25.** Moulded housing with the Navya lettering.

**Fig. 26.** The finished front end on the vehicle.

**Fig. 27.** Fixturing for repeatable assembly.

**Fig. 28.** Assembly movement through the line.

**Fig. 31.** Assembly line at the factory.

**Fig. 32.** Finished vehicles, ready to leave.

ICAT-certified and RTO registered as a cargo three-wheeler in November 2023. Astro Motors is manufacturing at scale, with a patent filed on a multi-gear manual transmission for EV.