Development of a dual injection silicone-based seamless automotive lamp for Euro NCAP Safety

In this study, we propose a high-luminance silicone optical system utilizing highly flexible silicone material to improve pedestrian safety. A dispensing process was employed to integrate high-transmittance diffusers into a single-layer silicone structure directly molded over LEDs. Additionally, the bezel, which interfaces with the silicone, was fabricated using a dual-injection process incorporating a high-reflectance material within a silicone matrix. By replacing conventional rigid components with silicone, this approach significantly enhances impact absorption while eliminating fragmentation risks. Furthermore, the flexibility of silicone enables effective impact energy dissipation, thereby reducing pedestrian injury severity. The proposed silicone-based center lamp not only meets the enhanced pedestrian safety requirements set by Euro NCAP but also enhances design flexibility and overall safety in automotive lighting.