Featured Engineered to Order Automotive Solutions

High Output Automation

A major automotive manufacturer needed a fully automated blast cabinet to process a variety of metal and composite parts—including brackets, housings, and engine components—as part of its high-volume production line. The primary objective was to achieve consistent, repeatable surface finishes using a recipe-driven interface that allows operators to quickly switch between part types while maintaining productivity, quality, and compliance with downstream coating and assembly requirements.
Clemco collaborated with the manufacturer’s production and automation teams to design a smart, modular blast system that could meet daily throughput demands and provide flexibility for multiple part SKUs. The design process included:
- Conducting process mapping and surface finish requirement analysis across multiple part types
- Developing pre-programmed “recipes” that adjust blast pressure, nozzle speed, media type, and cycle time automatically for each part
- Integrating robotic blast arms and programmable logic controls (PLC) to ensure precise nozzle movement and part manipulation
- Designing quick-change fixturing and efficient part loading systems compatible with existing production infrastructure
- Ensuring the system met safety standards and was built for continuous-duty operation in a 24/7 environment
Clemco delivered a turnkey, recipe-driven automated blast cabinet featuring:
- An intuitive HMI touchscreen interface that allows operators to select predefined blasting recipes by part number or barcode
- Fully automated robotic blasting arms for precise, repeatable coverage across varying geometries
- A robust media reclaim and filtration system to maintain media quality and minimize operating costs
- High-efficiency dust collection, sound insulation, and safety interlocks for clean, safe operation
- Scalable architecture for future integration with MES systems or downstream automation
The solution enabled the automaker to dramatically improve production consistency, changeover speed, and labor efficiency—delivering high-quality, inspection-ready parts with minimal operator intervention and maximum output.

A major automobile manufacturer required a large-format, high-performance blast room to clean and prepare vehicle frames prior to final assembly and coating. The objective was to remove mill scale, weld slag, and surface contaminants to ensure optimal adhesion for paint or protective coatings, all while maintaining strict production throughput requirements and surface finish tolerances. The solution also needed to align with the manufacturer’s lean production goals and operator safety standards.
Clemco partnered with the automaker’s engineering and facilities teams to create a tailored solution using its I2R™ engineered-to-order process. The design phase involved:
- Conducting on-site evaluations to map out available floor space, traffic flow, and environmental controls
- Engineering the room to handle oversized and heavy frame components with ergonomic access and efficient part movement
- Determining the ideal blast media type and flow rate to meet surface prep specifications without deforming structural members
- Designing advanced ventilation and dust collection systems to maintain air quality and visibility
- Building in automation readiness for potential future upgrades (e.g., robotic or semi-automated blasting)
Clemco delivered a purpose-built blast room system with the following capabilities:
- Heavy-duty part handling tracks or lift systems for safe, efficient movement of full-size vehicle frames
- Multiple operator stations with ergonomically positioned blast nozzles and PPE support
- High-efficiency media reclaim and recycling systems for continuous operation with reduced media waste
- Environmental controls, including advanced dust collectors, high-output LED lighting, and noise suppression
- Training and technical support to ensure smooth onboarding and sustained performance
The final solution enabled the manufacturer to achieve high-quality frame surface prep at scale, improve coating performance, reduce manual labor intensity, and maintain tight control over production line efficiency and compliance.

Frame Blast Room

A leading global automobile manufacturer needed a high-throughput, automated blasting system to prepare aluminum and cast intake manifolds prior to final engine assembly. The job required:
- Precise and uniform surface finishing to remove casting residues, flash, and contaminants
- Improved surface adhesion for coatings or gaskets
- Repeatable results to meet strict quality control requirements
- Integration into a fast-paced production line with minimal operator involvement
Clemco collaborated closely with the automaker’s production and engineering teams to develop a solution tailored to their engine assembly workflow. The design process included:
- Analyzing the geometry and variability of manifold types used across engine platforms
- Selecting the appropriate abrasive media and blast parameters to achieve optimal surface texture without damaging critical sealing surfaces
- Designing robotic nozzle articulation and part fixturing for consistent 360° coverage
- Ensuring the system met production line takt time and could interface with upstream and downstream automation
- Building in maintenance-friendly access, media reclaim systems, and integrated dust collection
Clemco delivered a fully automated blast cabinet equipped with:
- Robotic blasting arms programmed for precise, repeatable cycles on various manifold types
- Conveyor or rotary table integration to maintain continuous production flow
- Closed-loop media recovery and filtration for clean, sustainable operation
- An intuitive HMI interface for recipe management, part changeover, and system diagnostics
- A compact, durable cabinet designed for 24/7 industrial use
The result was a high-efficiency blasting solution that enhanced surface quality, supported stringent engine assembly standards, and delivered measurable gains in production consistency, labor efficiency, and downstream performance reliability.