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Starting with the lens, this will be thermoformed out of 0.25” 1/8” clear polycarbonate (or similar thermoplastic) which will require a mold to be designed.
At some point in time, the lens will be glued to the flanges on the hood and side panel, but this will create an ugly glue joint that will be visible from the outside of the car (due to the transparency of the lens). The way car companies hide this joint on windows is by painting a black border around the inside of the the transparent panel to cover the flange. Thus the 1st aesthetic component will be a layer of black spray paint around the border of the headlight. There will also be portion in the middle of the lens that will either be spray painted black or tinted since the lens is quite large compared to the lighting elements. This will require a stencil to control where the paint lands on the lens and possibly some research into how to apply window tint properly (avoid air bubbles, etc).
The next aesthetic elements are optically diffusing elements. These are pieces of plastic that diffuse and soften the light from the LEDs. Manufacturing will be mostly straightforward (gluing small pieces of plastic to the enclosures, maybe some minor thermoforming involved), but the materials, colours, and dimensions still need to be finalized.
The enclosures will likely be 3D printed due to how intricate they are and because that’s already how the hardware team makes board mounts and enclosures. The enclosures still need mounting points for the PCBs, they need to be logically split into smaller parts so that they fit in a 3D printer, and they may need some modifications to make printing easier.
To my knowledge, the PCBs are finished.
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