Spark Autometal specializes in manufacturing automotive components with intricate designs that are vital for production and adhere to stringent safety standards. To meet these demanding requirements, Spark consistently enhances its processes by adopting the latest manufacturing systems, staying updated with advanced technical knowledge, and fostering highly skilled expertise.
Tube Bending
Tube bending encompasses a range of specialized sub-processes supported by a multi-machine setup, including induction heating systems and hydraulic presses. Both cold and hot bending are performed with precision and efficiency. Automation and high productivity are achieved through robotic arms, which handle tasks such as homing, resistance heating, and executing the first and second bends. From picking up the raw tube to placing the finished bent part into the tray, the robot manages the entire operation seamlessly. This advanced setup has an impressive capacity to process up to 780,000 parts annually.
Welding
At Spark Autometal, welding is defined by precision, methodology, and safety. The extensive heavy fabrication process is executed in two stages: tack welding and full welding. Tack welding secures the child parts to the main component, streamlining the operator’s task during the full welding phase. Overhead Cranes (OHC) ensure smooth and efficient material movement throughout the process. To stay at the forefront of industry standards, Spark Autometal operates a dedicated welding training center. Here, operators receive regular training and are equipped with the latest welding techniques, ensuring excellence in every project.
Computer Aided Drawing
Our development team delves into every aspect of the new component to be manufactured. We use latest design tools to study the component model and design & develop jigs and fixtures to be used on the production line. This in-house capability helps speed up the process of sample component manufacturing. It gives clarity on how to manufacture the component exactly as per the drawing provided by the customer.
Tubular Fabrication
Fabrication involves a series of complementary and logically arranged processes. The first step is pressing, where the part transitions from its basic condition to the required form. Operations such as notching, piercing, blanking, and forming are executed on various machines. Every aspect, including the width of the welding bead, welding penetration, and gas flow, is automatically controlled. Additionally, the profile bending machine is capable of 3-axis bending, allowing the manufacture of several components made from different tube profiles for prestigious companies.
Surface Treatment
At Spark Autometal, surface treatment of vehicle accessories is essential for enhancing aesthetic appeal and corrosion resistance. Our advanced facilities feature Nickel-Chrome plating and Powder Coating processes, utilizing precise PLC-controlled systems to ensure components are cleaned, coated, and cured to the highest quality standards.
Product Testing
At Spark Autometal, some highly tenacious tests are used to rate the parts’ performance. After plating, a Salt Spray test deduces a part’s corrosion resistance and hence predicts its life. A Graphic Step Machine then measures if the thickness of the plating is adequate. For powder coated parts, a standard scratch test and then completely mechanical methods like flexibility test and impact test are used.
Assembly
With conveyorised lines and productive techniques, the assembly lines at Umasons Auto produce 2400 parts per day. The processes are carried out on various SPMs and are built with the specialty of interlocking. Use of Poka-yoke technique at each assembly stage minimizes human error. A deviated part out from a process is not processed at the next stage. Features like Photo-Sensors, First In First Out and Auto Shutdown make the system highly efficient.
Stamping
At Spark Autometal, our stamping process transforms flat metal sheets into precise components through punching, blanking, embossing, bending, flanging, and coining. This method ensures high-quality, consistent parts essential for various applications.
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