Born out of the supply chain challenges triggered by the COVID-19 pandemic, Nexus Labs (NL)—the engineering arm of the Sir Lanka-based Dilmah Group—is now charting a strategic global expansion. Building on its early success, NL is now exploring global opportunities—including in India—offering both mass-produced automotive components, custom solutions for vintage vehicle restoration and low-cost automation and engineering services. The company already has a presence in the Australian aftermarket, supplying precision parts for specialised needs.
Speaking to Mobility Outlook, Natheesan Selvaratnam (Manager -Engineering Innovations) of NL, said the company is already manufacturing high-precision components such as shims—used in engine assembly to finetune compression ratio, with tolerances measured in microns. He noted that NL’s ability to replicate aluminium engine heads and other complex parts locally marks a significant breakthrough. “With our foray into metal 3D printing, we are well-positioned to deliver cost-effective, high-quality parts that precisely match original specifications,” he added.
Joining the discussion, Darshana Alahakoon, Group Head of Engineering at MJF Group, explained that the group strategically invested in advanced engineering capabilities to locally manufacture high-precision components. Initially focused on maintaining the group’s sophisticated tea bagging and packaging machinery, NL has since expanded its scope to include remanufacture of critical machine parts and select automotive components.
With NL’s expertise in spare parts manufacturing, the division specialises in both metal and polymer-based components, leveraging advanced technologies such as 3D scanning, CAD/CAM design, and 5-axis CNC machining. Alahakoon noted that the company, while supporting the group’s internal requirements, now has excess capacity to serve external clients—particularly in the automotive sector. Backed by sustained investment in R&D, production technologies, and rigorous quality systems, NL is positioning Sri Lanka as a serious contender in global precision engineering and automotive component manufacturing.
Darshana Alahakoon and Natheesan Selvaratnam
According to Selvaratnam, the company’s core strength lies in delivering low-volume, high-complexity custom parts—particularly suited for restoration and retrofitting projects where conventional mass production is not viable. With strong in-house reverse engineering capabilities, the team can accurately reproduce components from physical samples or technical drawings, ensuring precision and authenticity.
NL has carved a niche in retrofitting and restoring antique and vintage vehicles, especially in markets like Sri Lanka, where sourcing rare components is often difficult due to import restrictions. Notable examples include machining a starter motor drive wheel for a Rover P8 when overseas procurement was not possible, and developing a custom mating plate to adapt a 1951 MG Magnette’s gearbox for use with a modern five-speed unit. These specialised projects highlight the company’s ability to deliver tailored, one-off solutions that address unique engineering challenges. A classic car with components turned out by NL will run the Classic Car Adventure from Delhi to the foothills of the Himalayas, in November.
Automation, Engineering, Cross-Industry Consulting
In parallel, the company offers cost-effective automation and engineering solutions tailored to the needs of small and mid-sized manufacturers, including indigenous brands and firms such as Force Motors. Its capabilities span low-cost automation, collaborative robots (cobots), and error-proofing mechanisms to enhance assembly line accuracy and minimise rejections.
Its consulting services cover end-to-end process optimisation, including factory layout design, quality enhancement, and cost reduction strategies. Particularly for companies unable to invest in high-end automation, NL provides frugal, effective alternatives that improve operational efficiency without excessive capital outlay.
These solutions are actively deployed across the group’s own network of seven manufacturing facilities and tea processing units, with a focus on space efficiency and productivity gains. The company is also selectively extending its engineering services to external clients, depending on the scope and nature of the requirement, explained Selvaratnam.
Engineering Innovation With Precision, Purpose
As an innovation catalyst within the Dilmah Group, NL supports both startups and established enterprises with end-to-end services ranging from prototyping and market validation to process optimisation, energy management, and regulatory compliance. Its automation capabilities span PLC and SCADA integration, robotics, and diagnostics, while business services include market research, branding, legal advisory, and IP protection.
Collaborations with global and domestic tech partners such as the IMA Group, IIT Madras Research Park, and Entuple E Mobility further amplify its impact. Drawing on deep sectoral knowledge across automotive, food, apparel, and energy, the multidisciplinary team combines agility with decades of leadership experience.
With over 30 years of cross-industry experience—from tyres and rims to garments and agriculture—the team approaches challenges with a multidisciplinary mindset, delivering practical innovations and agile problem-solving, Alahakoon added.
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