Case Study: Automotive & EV

Next-Gen EVSE Status Lighting Platform

Developed a modular, DFM-driven lighting platform with advanced electronics, optics, and mechanical integration for reliable EV charger status indication.

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01 The Challenge

Modernizing charging infrastructure required a robust, scalable approach.

As electric vehicle adoption accelerated globally, our client, a leading manufacturer of EV Supply Equipment (EVSE), identified a critical bottleneck in their manufacturing and field deployment operations. The existing status indication lighting solutions across their charger variants were fragmented. They required intensive manual assembly, specialized tooling, and suffered from inconsistent optical performance. Furthermore, deployed units struggled with outdoor reliability, particularly moisture ingress and UV degradation over time.

Reduce complex assembly processes to improve manufacturability.

Enhance reliability for harsh outdoor environments.

Lower power consumption without sacrificing visibility.

Enable seamless scalability across multiple charger variants.

02 The Solution

Unified Engineering Platform

We delivered a modular, DFM-driven lighting platform integrating electronics, advanced optics, and precision mechanical engineering.

Embedded Control

Custom embedded control board designed for low power consumption and high reliability.

Scalable Optics

Optimized LED optics providing uniform, high-visibility illumination in direct sunlight.

DFM Integration

DFM/DFA-driven architecture simplifying assembly while ensuring consistent quality and rapid deployment.

03 The Outcome

Our approach resulted in a production-ready platform that significantly improved manufacturability, performance, and long-term product reliability.

Achieved over 90% reduction in assembly time through architecture optimization, part consolidation, and DFM/DFA-driven design.

Reduced overall power consumption through optimized electronic architecture and power management.

Delivered a scalable, production-ready platform for high-volume manufacturing.

Enhanced field reliability through robust validation and thermal optimization.

Improved manufacturing efficiency by simplifying assembly and minimizing operator intervention.

Enabled faster commercialization with a validated design platform.

Capabilities Overview

Capabilities Deployed

5 specialized capabilities covering end-to-end product engineering and manufacturing.

Opto-Mechanical Engineering

Embedded Hardware

LED Systems

Design for Manufacturing

Environmental Testing

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