<p>Automotive components, such as two-wheeler frames, fuel delivery systems, and automotive link arms, require tubes to be welded together to create an integrated structure. These weld zones act as stress concentrators throughout the assembly when the components are subjected to structural loading during operation. High-stress areas can be mitigated by using either uniformly thicker tubes or tubes that are thickened only at their ends. The latter approach ensures an overall reduction in the weight of the entire assembly. Current state-of-the-art methods reveal various processes for manufacturing variable thickness tubes, including flexible rolling. However, the implementation of these processes is often limited due to economic constraints, such as high tooling investment and/or low productivity resulting from increased cycle times. This highlights the need for a more efficient method to thicken the ends of tubes while addressing the limitations of currently available methods. A new process is proposed for locally thickening the ends of electric resistance welded (ERW) tubes. The concept of this process is validated both numerically and experimentally. Moreover, the process is automated to make it production friendly. Details of process automation are highlighted. The results from numerical simulations regarding thickness increments closely align with the outcomes observed experimentally. Furthermore, a maximum thickness increase of 30% has been achieved in the tube. The characterization of the end-thickened tubes also demonstrates a significant improvement in their mechanical properties. The novel technique developed in this study is beneficial for automotive manufacturers aiming to produce lighter and more cost-effective vehicles.</p> Graphical Abstract <p></p>