Industries / Automotive / Lights

Automotive lights
production automation.

Complete, end-to-end production lines for modern headlight systems, delivering the absolute precision, delicate handling, and rigorous testing required for flawless optical performance and durability.
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Mastering the complexity.

Pagero's way

Flawless optical quality
Our systems guarantee the precise alignment of lenses, LEDs, and reflectors, ensuring perfect photometric performance and beam patterns.
Superior assembly integrity
We automate complex assembly and joining processes to create robust, perfectly sealed units that withstand the rigors of the road.

Headlamp and Taillamp production

Precision robotic assembly

Our automated solutions are engineered to handle the intricate assembly of modern vehicle lighting. We deploy precision robotics to expertly manage and place every delicate component, ensuring a perfect, damage-free build with absolute repeatability from the first unit to the last.
Delicate component handling (LEDs, optics, bezels)
Electronic component integration (PCBs, drivers)
Precision robotic fastening and securing
Automated adhesive and sealant dispensing
In-line quality and presence verification
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LENS-TO-HOUSING JOINING

Advanced joining for a perfect, durable seal

A permanent, weatherproof seal is critical for the longevity and performance of any modern headlight. Our expertise covers a range of advanced, automated joining technologies designed to create a robust and flawless bond between the lens and housing, guaranteeing reliability.
Hot plate and vibration welding
Ultrasonic welding solutions
Precision adhesive and sealant dispensing
Automated plasma surface preparation
Integrated leak and pressure decay testing
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GEOMETRY and PROFILE CHECKS

Verifying dimensional perfection

We ensure every headlight assembly meets its exact design specifications for a perfect fit and finish on the vehicle. By integrating advanced 3D vision and non-contact laser scanning, we perform rigorous geometry checks, aligning the component to its Reference Point System (RPS) to validate every critical dimension.
RPS (Reference Point System) alignment
3D surface and profile scanning
Gap and flushness measurement
Automated pass/fail decisions
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TRACEABILITY and DATA MANAGEMENT

The digital record of quality

We create a complete digital birth history for every headlight, providing unparalleled insight and traceability. Our systems capture and link component serial numbers to critical process data at every stage, creating a robust digital record for total quality assurance and compliance.
Component-level serial number tracking
Process parameter logging (torque, temp, volume)
Integrated barcode and character recognition (OCR)
Test result and validation archiving
MES and factory system integration
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Ready to drive your production forward?

Let's discuss your specific automotive manufacturing challenges
and engineer a solution that gives you a decisive competitive advantage.

Frequently asked questions (FAQs)

How do you handle delicate optical components like lenses and reflectors?

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We use specialized, low-force robotics equipped with custom-designed, non-marring end-effectors (grippers). This is often combined with 2D and 3D machine vision to guide the robot, ensuring every delicate component is handled and placed with extreme care and precision, preventing scratches or damage.

Can your systems handle multiple headlight variants on the same line?

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Yes. We design our production lines with flexibility as a core principle. By using intelligent robotic systems, adaptable tooling, and a robust control system, we enable you to produce multiple headlight variants (for example, for different trim levels or regions) with minimal or even automated changeover time.

What is RPS alignment, and why is it important for headlights?

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RPS (Reference Point System) alignment is the process of precisely locating a part in 3D space according to its official engineering datums. For headlights, this is critical to ensure a perfect fit with the vehicle's body panels. Our systems use non-contact sensors to measure the part against its RPS points, guaranteeing flawless gap and flushness for superior aesthetic quality.

How do you ensure traceability for electronic components inside a sealed unit?

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We integrate scanners at key stages to read barcodes or serial numbers on every critical electronic subcomponent, such as LED modules or control drivers, before the unit is sealed. This data is logged and linked to the unique serial number of the final headlight assembly, creating a complete digital birth history for 100% traceability.