Custom Lighting

You know your customer
We know lighting

Trusted by Leading Brands

  • Honda
  • Club Car
  • Harley-Davidson
  • Winnebago
  • John Deere
  • Hyster-Yale
  • Lotus
  • Navistar
  • BMW
  • Bobcat
  • Arch Motorcycle Company
  • Polaris
  • Kubota
  • New Flyer
  • Nikola
  • Paccar
Custom Lighting

How we build custom lighting

Before you scroll

Not every program needs its own tooling

A clean-sheet program earns its tooling back at volume. Below that, we start from a platform that is already certified and change what has to change. Six pieces to 60,000, and the answer is never "come back with a bigger order."

Look at semi-custom
VR photometric simulation: the beam pattern lighting a rural intersection from above VR photometric simulation: the beam pattern along a divided road with guardrail VR photometric simulation: a tractor's beam pattern across field rows

VR Virtual Reality

Explore your options, and approve your Customer's Experience before cutting tooling chips.

The VR driving simulator: triple screens, wheel, and seat running a night-road scene
Phase One

Concept

Every program starts with your requirements: the vehicle, the duty cycle, the volumes, and every market you plan to sell into. We work out feasibility, photometric targets, and program risk before anything is drawn. Your program manager is assigned on day one.

You get a straight answer, in writing, on what is possible, what it will cost, and how long it will take, while changes are still cheap to make.

Inside this phase
Application & duty-cycle analysisBenchmark studyPhotometric targetsRegulatory market mappingPackage & mounting constraintsBudget & timelineProgram risk reviewProgram manager assigned
Headlamp concept study rendered over ideation sketches
Phase Two

Design

Mechanical, optical, electrical, software, and styling engineering work in parallel, not in sequence. Simulation shows how the lamp will perform thermally, structurally, and optically before any tooling is cut. Industrial 3D printing puts a physical part in your hands in days.

You review parts and beam patterns, not renderings.

Inside this phase
MechanicalOpticalElectricalSoftwareStyling & renderingThermalCondensationMold flowStructuralVibrationPhotometryDesign for manufacturingIndustrial 3D printingRapid concept trials
CAD surface drawing of a lamp bezel and optics assembly
Phase Three

Validation

We write a DVP&R test plan for your program and run it in our own photometric and EMC labs. It ends in the approvals your markets require and the PPAP documentation your quality team expects.

We know the shortest path to approval in every market you sell into. Compliance is our job, not your risk.

Inside this phase
DVP&R test planPhotometric labElectromagnetic compatibilityEnvironmental & corrosionIP67 / IP69K sealingVibration & thermal shockPPAP submission
DOT certified ECE certified SAE standards Transport Canada compliant CCC certified, China AIS certified, India VSCC certified, Taiwan IP69K sealed
Phase Four

Production

Custom tooling, automated assembly, in-house SMT and PCBA, injection molding from 60 to 1650 tons, and vacuum metalizing, all on one campus. Because we build our own circuit boards, design changes move at our speed instead of waiting on a supplier.

Launch support and a continuous quality improvement program carry the work past start of production, not just up to it.

Inside this phase
Custom toolingInjection molding 60T–1650T1, 2, 3-shotVacuum metalizingIn-house PCBA / SMTAutomated assemblyWiring harness assemblyHigh mix / low volumeISO 14001IATF 16949CQI programLaunch support
Assembly lines on the J.W. Speaker production floor

Three plants. 403,000 sq ft. One integrated campus.

MADE IN THE GERMANTOWN · WISCONSIN USA ★★★
Start Your Program

Talk to an OEM specialist

Every custom program starts the same way: a short conversation about the vehicle and what the light has to do. Send the basics below and an OEM specialist replies within two business days.

Primary market segment *

Please choose the market that best represents your vehicle.

Demo form. Submissions are not stored.

Received.

An OEM specialist will review your application and reply within two business days.

Talk to an OEM Specialist