Case Study: Lazer Lamps validates screwless, lightweight automotive headlamp design and cuts hardware costs with SimScale

Lazer Lamps validated innovative automotive lamp designs with SimScale

Lazer Lamps, a British LED automotive lighting manufacturer, needed to reduce weight and assembly complexity on a new motorsports headlamp by holding the reflector with a plastic spring instead of screws. To validate stresses, fatigue and long‑term creep for a 10‑year service life, Lazer Lamps turned to the SimScale cloud-based FEA simulation platform.

Using SimScale, engineers uploaded the component, used automated meshing and public project templates, adapted material properties, and ran stress and creep analyses; SimScale’s post‑processing confirmed the screwless design meets mechanical requirements with no permanent plastic deformation or unacceptable creep over ~10 years. The SimScale-driven simulation took about 1 hour, cost €10, and supported roughly $40k average hardware savings while validating the design for production.

Lazer Lamps