FAQ
Frequently Asked
Questions
Answers to common questions from procurement managers and design engineers about SAPL's manufacturing processes, quality management, export capability, and RFQ process.
About SAPL
4 questionsWhere is SAPL located and what does the company manufacture?
Sadguru Autocomponents Pvt. Ltd. is headquartered and manufacturing near Pune, Maharashtra, India. We manufacture aluminium die cast components — primarily via high pressure die casting (HPDC) and gravity die casting (GDC) — for OEMs and Tier-1 suppliers in the automotive, industrial, agricultural, electrical, and medical sectors.
What is SAPL's production capacity?
SAPL operates five HPDC machines with clamping force ranging from 180 to 450 tonnes, plus gravity die casting facilities and an in-house VMC machining centre. Current combined annual capacity exceeds 800 metric tonnes of finished aluminium castings. Machine utilisation and scheduling details are available on request for supply qualification.
Does SAPL have ISO certification?
SAPL holds ISO 9001:2015 certification for design, development, and manufacture of aluminium die castings. We are actively working toward IATF 16949 certification for the automotive supply chain. Our current ISO certificate is available on request as part of our supplier qualification pack.
Can SAPL supply directly to European OEMs?
Yes. SAPL has established export programmes supplying components to OEMs in Poland and Italy. All export documentation is produced in English. We manage ocean freight logistics, customs documentation, and certificate of conformance for each shipment. Contact our export team for a qualification package.
High Pressure Die Casting
5 questionsWhat is the maximum component size SAPL can produce via HPDC?
Our largest HPDC machine operates at 450 tonnes clamping force, enabling components with a projected area up to approximately 450 cm². In practical terms, this covers components up to roughly 500 × 350 mm projected size. Components outside this envelope may be achievable via gravity die casting or through discussion with our engineering team.
What aluminium alloys does SAPL work with?
The primary alloys used at SAPL are ADC12 (equivalent to A383/EN AC-46000), A380 (equivalent to ADC10/EN AC-46100), and LM25 (equivalent to A356/EN AC-42100). ADC12 is used for most HPDC programmes. A380 is specified for automotive and higher-strength applications. LM25 is used for gravity die casting programmes, including medical-grade components. Other alloys can be discussed for specific applications.
What surface finish can SAPL achieve on HPDC components?
As-cast surface finish on HPDC components is typically Ra 1.6–3.2 µm depending on die condition and component geometry. Features requiring Ra ≤ 0.8 µm (sealing faces, bearing bores, mating surfaces) are achieved through CNC finish machining. For cosmetic surfaces, paint-ready finish or powder coating with pre-treatment is available.
Can HPDC components be heat treated?
Standard HPDC components are generally not suitable for T6 heat treatment because sub-surface gas porosity can expand during the solution treatment cycle, causing surface blistering. For components requiring T6 treatment and the associated mechanical property improvement, gravity die casting with LM25 alloy is recommended. SAPL can advise on the most appropriate process for your application.
Does SAPL use primary or secondary aluminium alloy?
SAPL uses primary aluminium alloy as standard for all production programmes. Alloy ingots are sourced from qualified suppliers and accompanied by heat certificates confirming chemical composition. Composition is verified by in-house optical emission spectrometer (OES) on each heat. Secondary (recycled) alloy is not used in production without explicit customer agreement.
Quality & Certifications
4 questionsWhat quality documentation does SAPL provide with shipments?
Every SAPL shipment includes: a Certificate of Conformance confirming the parts meet the agreed specification, dimensional inspection report for critical characteristics, material certificate from the alloy supplier, and batch traceability records linking the shipment to the specific production and inspection records. PPAP documentation (Level 3, AIAG format) is available for automotive customers.
Can SAPL prepare PPAP documentation for automotive customers?
Yes. SAPL prepares PPAP packages to AIAG Level 3 as standard for automotive programmes. This includes: Dimensional Results, Material and Performance Test Results, Process Flow Diagram, Process FMEA, Control Plan, Measurement System Analysis (Gauge R&R for critical characteristics), Process Capability Study (Cpk), and Sample Warrant (PSW). PPAP preparation is included in the tooling qualification cost for new programmes.
How does SAPL control porosity in die castings?
Porosity control is managed through a combination of process and tooling design. The die geometry, gating, and venting are designed in simulation before tool machining. In production, shot parameters (fill speed, intensification pressure, die temperature) are set and monitored per programme. 100% X-ray inspection is available for pressure-critical or safety-critical components on request. For structural components, hydrostatic pressure testing is standard.
What metrology equipment does SAPL operate?
SAPL's inspection department operates: a coordinate measuring machine (CMM) for 3D dimensional inspection, an optical emission spectrometer (OES) for alloy composition verification, surface roughness measurement instruments, hardness testing equipment, and calibrated go/no-go gauges for high-volume production characteristics. All measuring equipment is calibrated on a scheduled basis with calibration certificates maintained in our quality system.
Exports & International Supply
5 questionsWhich countries does SAPL export to?
SAPL currently exports to customers in Europe, with active programmes in Poland and Italy. We are actively expanding our European customer base. All documentation is produced in English. For other regions, please contact us — our export process is designed to accommodate customers globally.
What incoterms does SAPL quote on?
SAPL typically quotes on FOB Nhava Sheva (Mumbai) or CIF to destination port. Ex-works (Pune factory) is available for customers managing their own freight. The preferred incoterm is agreed at the time of quotation and confirmed in the purchase order.
What is the typical lead time for export shipments?
Production lead time for established programmes with tooling in place is typically 4–6 weeks from purchase order to shipment. Ocean freight transit from Nhava Sheva to European ports is 20–28 days. Total replenishment lead time from purchase order to delivered stock is typically 8–12 weeks. For first-article and PPAP shipments, allow an additional 2–4 weeks. Blanket orders with monthly releases can reduce effective lead time significantly.
Who handles export documentation?
SAPL's export team handles all export documentation, including commercial invoice, packing list, certificate of origin, bill of lading or airway bill, and any customer-specific quality documentation. For EU imports from India, we prepare documentation compliant with the applicable trade agreement frameworks. A dedicated export coordinator is assigned to each international customer account.
How does tooling ownership work for export customers?
Tooling paid for by the customer is recorded as customer property in SAPL's tool register and is clearly identified in storage. It is maintained at SAPL's facility for the duration of the production programme at no additional charge. On programme end, tooling can be collected by the customer, held in storage by prior agreement, or scrapped with written authorisation.
RFQ & Quotation Process
5 questionsWhat information does SAPL need to provide a quotation?
For an accurate quotation, SAPL requires: a STEP or IGES 3D model of the component, an annotated 2D drawing with critical dimensions, tolerances, and surface finish callouts, the material (alloy) specification, the required annual volume, and any specific quality requirements (e.g., pressure testing, surface treatment). Quotations without 2D drawings are possible but will carry wider tolerance assumptions.
How long does it take to receive a quotation from SAPL?
Standard quotation turnaround is 72 hours from receipt of complete documentation (STEP + 2D drawing). Complex components requiring extended DFM analysis or tooling cost estimation may require 5–7 working days. Preliminary budgetary quotations for simple components can sometimes be provided within 24 hours.
Does SAPL charge for DFM analysis?
No. DFM (Design for Manufacturability) analysis is provided at no charge as part of the quotation process. Our engineering team reviews the geometry, identifies any features that may present manufacturing challenges, and provides written feedback alongside the quotation. DFM recommendations are offered — not imposed — and the customer makes the final decision on any geometry changes.
What is the minimum order quantity?
There is no fixed minimum order quantity. For tooling recovery and cost efficiency, HPDC programmes are most economical at annual volumes of 5,000 units or above. For lower volumes, gravity die casting or machined alternatives may be more cost-effective, and SAPL will advise accordingly. For export programmes, practical minimum shipment sizes are determined by freight economics — typically one or more CBM per shipment.
Can SAPL accept purchase orders in foreign currencies?
SAPL raises invoices in Indian Rupees (INR) for domestic customers and in USD or EUR for international customers, by agreement. Currency confirmation is part of the initial commercial discussion. Bank transfer is the standard payment method; letter of credit arrangements can be discussed for larger programmes.
Technical Questions
5 questionsWhat dimensional tolerances are achievable in HPDC without machining?
As-cast HPDC tolerances depend on feature location and die construction. For features fully within one die half: typically ±0.1 to ±0.15 mm. For features across the parting line: ±0.2 to ±0.3 mm. Bore diameters achieved through die-cast cores: ±0.2 to ±0.3 mm. For tighter tolerances (±0.02–0.05 mm), CNC machining is applied as a secondary operation.
Can SAPL machine components after die casting?
Yes. SAPL operates an in-house VMC machining centre with 4th-axis capability. CNC machining is performed as part of the integrated production flow — castings go directly from casting to machining within the same facility without being shipped to a third party. Machining tolerances achievable are ±0.02 mm for standard features, with tighter tolerances achievable for specific operations.
What powder coating colours and finishes can SAPL provide?
SAPL's in-house powder coating line produces a range of standard RAL colours and textures (gloss, semi-gloss, matt, texture finish). Custom RAL colours are available with minimum batch quantities. The pre-treatment line uses a 5-tank nano-ceramic process providing excellent adhesion and corrosion resistance. Salt spray resistance of 500+ hours is achievable for standard powder coat on pre-treated aluminium.
Does SAPL offer contract manufacturing for machined components (non-casting)?
SAPL's primary capability is aluminium die casting with integrated machining. We do not operate as a standalone machining job shop. However, for components that are part of an existing casting programme, SAPL can machine additional operations such as tapping, drilling, reaming, and profile milling as part of the complete supply.
Can SAPL assist with tool repair or modification for existing tooling?
Yes. SAPL's tool room performs die repair, steel insert replacement, and planned maintenance on all production tooling. For customer-owned tooling transferred from another supplier, we can assess condition, perform necessary refurbishment, and qualify the tooling for production at SAPL. Contact our engineering team with the current tool drawings and production history.
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Go Deeper
Technical guides and insights
Detailed technical articles written for procurement managers and design engineers.
High Pressure Die Casting Guide
Process overview, tolerances, alloys, and DFM rules for design engineers.
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