The Manufacture of a New Generation of Headlamp Reflectors
This paper reviews the development and implementation of a radically new manufacturing system for the production of advanced automobile headlamp reflectors using a thermosetting plastics material. The new system has replaced the traditional method which involved pressed and fabricated steel reflectors. This project has required wide ranging interaction of many business functions. They include sales and marketing, material process and production research and development, product design and development, and factory production engineering. Product design in particular has benefited from the improved optical performance of the new reflectors, providing beams of a higher photometric output and having a more closely defined pattern. This has been achieved whilst product quality, durability and competitiveness have been improved. In addition, the high aspect ratio headlamps made possible by the plastics reflectors have allowed lower vehicle bonnet designs, resulting in lower coefficients of drag and thus improved fuel economy.