Processes – Spark Autometal

Our Manufacturing Processes

Advanced techniques and precision engineering that define automotive excellence

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.

Our Core Processes

Explore our advanced manufacturing techniques that ensure precision, quality, and
reliability in every component we produce.

Our tube bending facility is equipped with advanced CNC bending machines, enabling critical bends with tight radii and complex geometries. We deliver consistent results across a wide range of materials and diameters, ensuring precision, repeatability, and efficiency for industrial applications in transportation, robotics, and engineering systems.”

“Our advanced laser cutting facility delivers precision and consistency across critical shapes and complex geometries. With CNC‑controlled systems, we achieve repeatable results on a wide range of materials and thicknesses. Enabling the production of large, accurately formed components for industrial, automotive, and engineering applications.”

Machining facility integrates CNC turning, conventional lathes, and advanced CNC Traub machines to deliver precision components across a wide range of sizes. From prototypes to high‑volume production, we specialize in critical machining of parts with consistent accuracy, superior surface finish, and repeatable quality.

This facility covers fusion welding (TIG, MIG), brazing (manual & induction), and resistance welding (spot & projection), reinforced by robotic automation and SPM solutions. Together, these capabilities enable the company to deliver high-quality, precision welds for both mass production and critical applications.

The company’s plating facility combines an automated plant with advanced chrome, nickel, and zinc plating processes, delivering durable, corrosion-resistant, and aesthetically superior finishes. This capability supports industries ranging from automotive and consumer goods and industrial machinery, ensuring both performance and visual appeal.

The company’s powder coating facility combines aesthetic excellence with strong corrosion resistance, supported by a dedicated testing laboratory to guarantee performance and reliability. This integrated approach ensures that every coated component meets the highest standards of durability, appearance, and quality assurance.

The company’s injection moulding facility, with machines up to 250 tonnes, offers flexibility across multiple materials and industries. By combining advanced equipment, versatile polymer processing, and rigorous quality control, the facility delivers precision-engineered plastic components for diverse industrial supply chains.

The company’s stamping facility, with machines of various tonnages and a monthly capacity of 200 tonnes, delivers precision-engineered stamped components across diverse materials and industries. By combining advanced equipment, versatile material processing, and rigorous quality assurance, the facility ensures consistent, high-quality production manufactured entirely in-house tooling.

Our company specializes in heavy fabrication, delivering precision-engineered structures and components for industrial applications. With advanced machinery, skilled expertise, and robust quality control, we handle large-scale projects from design to final assembly, ensuring durability and efficiency

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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.

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.

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.

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.

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.

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.