Sealing of automotive optics (headlights, lamps, LED modules)
Modern automotive optics operate under conditions of vibration, temperature fluctuations, high humidity, and constant UV exposure. The tightness of headlights and lighting modules directly affects driving safety: moisture ingress leads to fogging, reflector corrosion, and electronic failures.
MAE TECH offers automated solutions for applying gaskets and adhesive systems in automotive optics production. The FIPFG (Foam-in-Place Gasket) technology enables the creation of seamless gasket contours on headlight housings and lenses, ensuring perfect joint geometry and compliance with IP standards. Our systems handle transparent and colored materials (PUR, MS polymers, silicones) that are compatible with UV curing and resistant to high temperatures. When necessary, surface pretreatment such as plasma activation or primer application is used. Precision servo-driven dispensers ensure consistent bead thickness and a clean, aesthetic finish without overflow.
Repeated opening and closing of the housing panels of heating, ventilation, and air conditioning systems, as well as service doors, is possible while maintaining a constant sealing effect
Automation reduces the number of defects, increases efficiency, and lowers costs. MAE TECH solutions are easily integrated into automotive production lines, providing full control over the parameters of each cycle and can be adapted to various sizes of headlights and lighting modules — from compact LED units to large optics for heavy-duty vehicles.
Technological challenges
Technology comparison table
Criterion | Rubber Gasket | Polyurethane Foam (FIPFG) |
| Sealing | Joints and gaps – risk of leaks | Seamless contour – absolute sealing |
| Durability | Ages quickly, cracks | Retains properties for decades |
| Resistance to vibration and temperature fluctuations | Prone to shifting and damage | Elasticity and shape remain unchanged |
| Design flexibility | Limited to standard profiles | Any contour and profile based on CAD model |
| Appearance | Visible joints, glue marks | Aesthetic, uniform premium-class bead |
| Logistics | Need to store dozens of sizes | Applied directly on the product |
| Production process | Manual cutting, placing | Automation, fewer errors |
| Waste and rejects | High waste | Practically eliminated |
| Cost of ownership | Cheaper initially but higher operational cost | Fast payback |
