Manufacturing Technology
Equipment Design and Manufacturing
Coating, assembly, thermal, cleanroom, and logistics equipment and lines, designed and built in-house.
Overview
We have the in-house capability to engineer, design, build, automate, integrate, commission, and optimise the equipment and production lines used across the processes of the automotive lighting industry.
The work starts with process engineering and concept design and covers mechanical and electrical design, control and automation systems, robotics, fabrication and assembly, integration, commissioning, and performance optimisation of equipment and lines.
Our experience with dedicated equipment lets us design solutions around the product, production volume, process requirements, level of automation, and production conditions. A large share of the equipment and lines used in our production is designed and developed in-house.
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Coating and Metallization Lines and Equipment
- Lines
- Hard coatingBase coating (reflectors and plastic parts)Anti-fog
- Machines
- Vacuum metallizationPVD
- Systems designed
- Part handlingSpray and coatingThermal and UV curingMixing and dosingProcess control and automation
In coating and metallization, our in-house capability covers designing and building complete lines and developing dedicated technologies for the requirements of each process.
This includes hard coating lines, base coating lines for reflectors and plastic parts, and anti-fog lines. In these projects we design the process systems, part handling, spraying and coating, thermal and UV systems, mixing and dosing, and process control and automation to suit the product and production volume.
For metallization and advanced coatings, we design, engineer, build, localise, commission, and optimise vacuum metallization and PVD machines in-house. These machines are developed specifically for the processes and products of the lighting industry and bring mechanical, vacuum, control, automation, and process systems together on one in-house platform.
This lets us develop and build dedicated solutions for new processes and adapt equipment to the needs of different products and coating and metallization technologies.
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Automatic and Semi-Automatic Assembly Lines and Stations
- Joining and assembly
- Adhesive dispensingPlasma treatmentLens assemblyControlled screwdrivingSealingInter-station transfer
- Plastic welding
- VibrationUltrasonicHot plate (machines built in-house)
- Testing
- In-line testingEnd-of-line testingLeak testFunction and light test
We design and build assembly lines and automatic and semi-automatic stations for different families of automotive lighting products.
Depending on the product and the level of automation needed, these lines combine a range of joining and assembly technologies, including adhesive dispensing, plasma treatment, lens assembly, precise controlled screwdriving, sealing, and transfer between stations.
In plastic welding, we design, engineer, commission, and optimise vibration, ultrasonic, and hot plate welding processes. The hot plate machines the process needs are designed and built in-house, and these technologies can be developed and integrated to suit each product and line.
We also design and build in-line and end-of-line test equipment for each product's requirements, including lamp leak testers and function and light test equipment. It is integrated into the lines so quality is checked at the point of production, at the right moment in the process.
Lines and stations are designed around cycle time, production volume, product type, level of automation, and process requirements, and can be integrated with control systems, robotics, and test equipment.
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Thermal, Washing, Cooling, and Process Support Equipment
- Equipment
- Thermal lacquer curing ovensOvens and washing equipmentThermal annealingEquipment and mould coolingAutomatic BMC reflector washing
A large part of our equipment work goes into the equipment needed for thermal management, part preparation, and process support.
This includes curing ovens for thermal lacquers, ovens and washing equipment, thermal annealing units, cooling systems for equipment and moulds, and automatic washing equipment for BMC reflectors.
This equipment is designed for each process and line. It keeps process conditions stable and repeatable, keeps equipment performing, and prepares parts properly for the next production steps.
Cooling systems are designed for the thermal needs of machines, moulds, and processes, and can be developed as an integrated part of equipment and lines.
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Cleanrooms and Controlled Environments
- Used for
- Optical part productionCoatingAnti-fogSensitive assembly
We design and build cleanrooms and controlled environments to suit the requirements of processes and production lines.
They are designed around process requirements, product type, production volume, and the required cleanliness level, and include the systems and environmental conditions that sensitive production processes need.
These environments are used for processes such as optical part production, coating, anti-fog, and some sensitive assembly steps, and are integrated with the equipment and needs of each line.
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Logistics and Packaging Equipment
- Scope
- Handling and transferIn-plant logisticsPackaging
Our equipment capability also covers handling, transfer, in-plant logistics, and packaging of parts and products.
This equipment is designed around material and product flow, part type, and protection and transfer requirements, to reduce manual handling, move parts safely, keep material flowing in order, and improve logistics efficiency.
Designed as part of production flow engineering, logistics and packaging equipment connects the transfer of parts between processes and production stages.
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Engineering, Automation, Integration, and Commissioning
- Disciplines
- Mechanical engineeringElectrical and controlAutomationPLCRoboticsPneumaticsFabrication and assemblySystem integration
Our equipment capability goes beyond mechanical fabrication. Equipment projects are run by our own specialist teams, from defining the need and process engineering through design, manufacture, automation, integration, and commissioning.
This covers mechanical engineering, electrical and control, automation, PLC, robotics, pneumatics, fabrication and assembly, and system integration.
After manufacture, equipment and lines are brought into service and evaluated through integration and commissioning, and can be optimised and developed further based on actual production performance.
This lets us turn process needs into production lines, automatic and semi-automatic stations, and dedicated equipment ready for operation, and develop solutions in-house for the different products and technologies of the automotive lighting industry.
Project path
- 01Requirement definition
- 02Process engineering
- 03Design
- 04Manufacture
- 05Automation
- 06Integration
- 07Commissioning
- 08Optimisation
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