As the global population continues to grow at a phenomenal rate, the automotive and engineering sector worldwide has been witnessing tremendous growth in recent times. However, the heightened competition that currently persists across markets has forced companies to engage in rigorous R&D and innovation to make the vehicles stronger, more lightweight, fuel-efficient, and perform better in all conditions. While this has resulted in a huge demand for forged and machined automotive components, the widespread EV adoption worldwide has added further fuel to the industry growth. As per a recent report from Persistence Market Research, the global forged automotive components market which is currently valued at $50.3 billion is expected to amount to $70.7 billion by 2032, showcasing a CAGR of five percent during the forecast period.
The situation is no different in India. Owing to the global demand as well as numerous initiatives by the government to nourish the manufacturing sector in the country, the forged & machined automotive components manufacturing in India is thriving incessantly in recent times. Amidst such encouraging yet hypercompetitive market conditions, one company that stands a notch higher than the rest through its innovation-driven product portfolio, client-centricity and high quality standards is Sunstar Precision Forge. Based in Greater Noida, Sunstar Precision Forge was established in 2005 with a vision to provide best-in-class forged & machined components and be a one-stop shop for material cutting,
hot forging, heat treatment, die design & manufacturing, machining, sub-assembly and logistical needs of diverse industries worldwide. Today, with a manufacturing facility spanning 80,000m2, the company has cemented its position as one of the leading manufacturer and supplier of a wide range of forged, machined & sub-assembled components to automotive (includes Passenger Vehicles, EV), agriculture and off-road/HCV-CV sectors in India, U.S., Europe, Mexico, China, Australia and Brazil.
Customer-centricity at the Core
A noteworthy highlight of Sunstar Precision Forge is its ability to clearly comprehend diverse customer challenges or requirements and accordingly provide custom solutions. The company continuously invests in advanced technologies such as press forging, AI, automation, and IoT to enhance precision and efficiency in forging and machining. Further, its R&D team collaborates with global experts to develop new materials, improve product designs to get best yield, and reduce cycle times. By adopting Industry 4.0 principles, Sunstar Precision Forge has also optimized its supply chain, ensuring better quality and on-time delivery for our global customers for PV/EV segment, Off highway-CV/HCV and agriculture segment.
Sunstar Precision Forge's relentless focus on capability building is evident from its recent investments to bolster its forging capacity with the addition of new 4000T and 2500T presses, complementing its existing lineup ranging from 500T to 4000T. All presses are seamlessly integrated with IBH automation, featuring pyrometer-based, three-way Poka Yoke systems to ensure billet temperature accuracy. A real-time SCADA system and controlled cooling conveyors further enhance forging quality and consistency. On the machining front, Sunstar Precision Forge has added next-generation, fully automatic machines from Muratec Japan, offering features such as auto loading/unloading, zero-operator involvement, in-process inspection, and multi-operation capability within a single unit.
“Along with a robust array of advanced machinery, including CNCs, VMCs, HMCs, VTLs, angular head grinders and surface grinders, we have also invested significantly in specialized processes such as induction hardening, spline cutting, broaching, MIG welding, and thermal spray stations for molybdenum coating. We have our own in-house metallurgical lab that works closely with our R&D team to provide customized forging and machining solutions as per customers’ every requirement”, says Dr Shrikrishan Yogi, Group CEO & Sr. Executive Director, Sunstar Precision Forge.
Keeping in mind the numerous supply chain disruptions happening due to the current geopolitical crises worldwide, Sunstar Precision Forge has adopted a local supply chain strategy wherein it has local warehouses in every region that it caters to, ensuring quick material availability whenever needed.
Further, the company also leverages real-time data to monitor demand, predicts the material demand for specific regions and accordingly stockpiles its warehouses there to cut-down its delivery times. This not only sparing the customers of any downtime in their production process, but also saves a lot of money in terms of logistics and transport costs as well.
Quality & Sustainability The Prime Focus
Following a strict ‘no compromise’ approach towards its service quality, Sunstar Precision Forge has integrated computer vision cameras and AI-integrated defect detection system for real-time monitoring and inspection with minimal human intervention. While having an inline gauging system facilitates 100 percent accuracy and quality check during production, the statistical process control and data analytics enable lean manufacturing practices, predictive maintenance and optimized processes with reduced wastage. Additionally, the company also uses a comprehensive range of testing and evaluation methods to ensure that its products meet the highest standards of quality and durability.
“We believe in process excellence and efficiency at every stage of the manufacturing cycle and management systems. Our tests are designed to simulate a real-world operating condition and detect any potential defects before the products reach the customer. We also strive to integrate sustainability in all our functions, including usage of ecofriendly & recyclable materials, solar panel installation in our manufacturing plant, zero liquid discharge system, waste recycling, and rainwater harvesting to supplement the water needs of the facility”, further explains Dr Shrikrishan.
Star-studded Journey
Till date, Sunstar Precision Forge has successfully catered to an elite clientele comprising of globally renowned names such as Tata, Mahindra, Honda, Daimler, CNH, VECV, JCB, Jaguar Land Rover, Dana, Cummins, Sona Comstar, Trelleborg, AAM, Comer/ Walterscheid and many others.
To further ensure trust among all its stakeholders, the company also holds numerous certification such as the ISO 9001:2015, IATF 16949:2016, ISO 45001:2018, and ISO 14001:2015. Owing to such exceptional track record and industry benchmark practices, it has also received numerous awards and recognitions that include Best Quality Performance by Brakes India, followed by Dana, Cummins, Best Supplier (Quality) by Trelleborg, Supplier Performance Award by Honda, Best Commodity Supplier (Quality) by Automotive Axel and Best Supplier (New Product Development) by Spicer, and most recently, the Best Vendor Award by Automotive Axle and Cummins in 2025.
To further improve business outcomes, Sunstar Precision Forge has implemented a suite of globally benchmarked practices such as Total Quality Management (TQM), Total Productive Maintenance (TPM), Lean Manufacturing, and Energy Conservation. The company is also embracing the Total Cost Management (TCM) system to identify and eliminate inefficiencies across operations. Further, it’ll maintain a sharp focus on safety and sustainability through a robust integration with its Safety, Health, and Environment (SHE) management system.
Quality being the number one priority for us, we believe in process excellence and efficiency at every stage of the manufacturing cycle and management systems
“We’re also working with Sona Comstar and JLR, where we not only gave a solution but also ensured that the engineering, logistics and management teams of both the firms work together to achieve high precision and good yield forgings. Also, over the last two years, we’ve been a supplier of largest EV OEM at U.S. through Tier-1, where a large portion of the forging and machining is done by us, and further processing at Tier-1, and supplies it to world largest EV OEM at US”, proudly adds Dr Shrikrishan.
The Path Ahead
At its core, Sunstar Precision Forge continues to live its philosophy ‘Inspire Perfection’, as proudly explained by Anooj Dharm Garg (Founder & Managing Director). This motto fuels a daily culture of innovation and continuous improvement, inspiring employees, customers, and partners to never settle for the ordinary, but to strive to be better, every single day. Under the visionary leadership of Anooj, Dr Shrikrishan and Raghav Goel (Director), Sunstar Precision Forge has charted an ambitious growth plan to triple its turnover by 2030. This strategic roadmap includes significant capital investments, such as establishing a new manufacturing facility in South India, and diversification into emerging segments like cold forging and aluminum forging.
In parallel, Sunstar Precision Forge is actively exploring strategic acquisitions of complementary businesses both in India and globally, aimed at further strengthening its footprint in the precision engineering domain. With a forward-looking mindset, Sunstar Precision Forge is rapidly expanding its portfolio of customized forged and machined components for global industry leaders. The company is now poised to become one of the largest global producers in two to three key product categories within the next few years.
“Innovation and transformation are at the heart of our operations, and going forward, we’ll continue investing in latest technologies such as forging presses automation and AI to enhance the precision and efficiency of our forging machines. Further, we’re also looking forward to implement Industry 4.0 principles more into our operations to optimize our supply chains and ensure better quality & timely delivery to our customers”, say Dr Shrikrishan & Raghav.
“Customer engagement from the design stage itself brings immense value”, Dr Shrikrishan & Anooj notes. “It enables us to offer cost-optimized, performance-driven solutions tailored to evolving needs”.
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