Lighting

MGRD’s lighting development services are provided both directly to carmakers and indirectly to systems and components suppliers.

The evolution of car design has seen the dimension of the external lighting systems, specifically headlights and position lights, increasing to occupy a significant portion of the vehicle. At the same time, the evolution in the level of design complexity, of lighting and reflector sources and functional elements has made headlights and position lights a distinctive factor in the brand of a vehicle.

Such factors make the process of developing these systems very articulated. MGRD is able to bring together a multiplicity of competences which, managed with the same approach used for the major vehicle systems, also make it the ideal partner for lighting systems. Described below in stages all the activities which characterise their development and which MGRD can provide both as a complete process or as a single support activity for the customer. MGRD has gained a wealth of experience in the development of the most up-to-date lighting systems and is able to deal with customers’ requirements by integrating itself, thanks to FLASH, with all operational situations concerning the development as well as with the related departments of the customer and the suppliers involved.

MGRD’s main development activities are:

  • Lamps concept definition:
    • Freehand sketches
    • Digital sketches
    • Final sketches
    • 3D style surfacing (from MGRD sketch or customer style department direction)
  • Hyper realistic renderings
    • Using class B and A surfaces, hyper realistic rendering will facilitate the style decision process and product content definition. Content requirement and the complexity of modern lighting systems are finding important solutions with this cutting-edge virtual technology
  • Benchmark:
    • Lamp Dismantling
    • Photo-scan
    • Library availability for all the benchmark already done.
    • Test and laboratories analysis management or realization
  • Installation/ and regulation check - macro feasibility:
    • Feasibility for regulation/homologation compliance
    • Lamp positioning on the vehicle verifications, visibility Angles analysis and optical surface definition.
  • Lamp system Feasibility:
    • Internal lamp element packaging
    • Overall dimension feasibility
    • Fixing definition
    • Gap condition analysis with neighboring components
    • Tolerances analysis (with the Use of 3DCS software)
    • Overall dimensions
    • Optical analysis and feasibility. Development of certified optical surfaces with the ASAP software and internal MGRD software.
    • Definition of style as mechanical and photometric part
    • Definition of construction technologies
    • Style surface updating
  • Lamp system engineering:
    • Complete engineering of the components and drawings creation
    • Optical design with ECE, SAE regulations, … with ASA e OPTIX software
    • Design and mathematical rendering through CAD 3D o Hyperrealism software. Studies management and mathematical models through the use of solid modelling programs and KINEMATICS.
    • Our software offers the following capabilities:
      • 3D solid e parametric modelling
      • Interfaces control (visual mock-up)
      • Base Renderings or hyper realistic
      • Weight monitoring
      • Tolerances virtual calculation and creation of virtual model starting from production numbers.
      • Leverage and actuator-connected components for moving systems.
      • Kinematics model and minimum clearance of moving parts with neighbouring parts
      • Realization of drawings or 3D annotation according to customer standards
    • Class A style surfacing
  • Construction of aesthetically pleasing and functional prototypes through the use of the following equipment:
    • Moulds in epoxy resins
    • Moulds in silicone rubber;
    • Through the stereo lithography process;
    • Through the sintering process.
    • Construction of optical prototypes realizing the reflecting surfaces in aluminium milled and polished.
  • Ministerial type approval for CEE, ECE AND USA
    • Our company has already been involved for many years in the Type Approval of rear light, heads lights and mirrors used in the automotive industry.
    • The type approvals include sampling, construction of supports for rear lights and headlights, photometric tests, technical reports and the Ministerial documentation.
  • Testing
    • Support during the testing phase
    • Testing management of MGRD supplier
  • Main lighting systems covered by MGRD:
    • Head light (including led technology)
    • Tail light (including led technology)
    • Indicator Light
    • Courtesy lights
    • License plate lights