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Engineering / Quality / Market entry

A problem found.
A product improved.

Three published NVEL project accounts: preventing water ingress, redesigning an installation failure and supporting a customer’s market-entry certification process.

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NVEL optical inspection station
Engineering in practice — NVEL optical QC station
01 / PROCESS QUALITY

From sample checks to every-unit leak testing.

Water ingress / 2023–2025 ↓02 / PRODUCT ENGINEERING

A housing redesign that protected the PCB.

N40D4 / 2024–2025 ↓03 / CUSTOMER DEVELOPMENT

Six sample rounds for a South Korean program.

LED headlight program / Asia ↓
01 / Process quality

Catch the leak
before shipment.

NVEL internal quality improvement
Fog lighting · 2023–2025

NVEL product testing area
NVEL testing area. Photo illustrates the factory environment; the case describes the separate air-tightness inspection process.

The problem

Before 2023, NVEL’s reported fog-light water-ingress rate was 0.15%. Although low as a share of total units, it was the largest warranty issue, accounting for 20% of returns. Physical submersion testing did not identify every defective unit.

The change

The factory switched to 100% automated air-tightness testing on the production line. Each unit was screened by leak rate before shipment, changing the release process from sampled checks to every-unit screening.

Published result0.15% → 0.06% → 0

The reported ingress rate first fell to 0.06%. In 2025, NVEL reported no returns caused by a manufacturing-related water-ingress defect. This result applies to that reported period and failure category.

02 / Product engineering

Design for how
it gets installed.

N40D4 series
Product engineering · 2024–2025

The problem

A newly launched N40D4 product returned at a reported 20% defect rate, with burned PCB boards. Engineers visited installation sites and identified longer replacement rear screws penetrating the housing and short-circuiting the board.

The change

The engineering team redesigned the aluminum body and repositioned the PCB to create clearance. The revised geometry prevented mounting screws from reaching the board.

Published resultFailure mode eliminated.

NVEL reported no further returns from this screw-to-PCB failure mode in the second half of 2025 after the redesign.

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03 / Customer development

Iterate the sample.
Support the market.

LED headlight brand
South Korean market-entry program

The brief

A customer needed support developing an LED headlight product for the South Korean market, including the KC and KATMO requirements relevant to the customer’s program.

The development

NVEL worked with the customer through six sample iterations, refining product dimensions, optical performance and material selection to support the certification process.

Published result6 sample iterations.

The customer obtained the KC and KATMO certifications described in the published project account. This is a program-specific result; it does not certify every NVEL product for that market.

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What these projects have in common

Follow the issue
back to its source.

Production checks, installation conditions and market requirements all influence the finished product.

Find the cause

Describe the failure, affected SKU and installation conditions. The more specific the evidence, the more useful the engineering review.

Change the relevant step

In these examples, the response was a release-test change, a mechanical redesign or an iterative product-development program.

Review the result in context

Read each outcome alongside its product, failure category and time period. A reported project result is not a universal performance guarantee.

Project accounts are based on NVEL’s published homepage. Client identities remain confidential. Ask your sales contact for references relevant to your product and market.

Your next step

What problem should your next supplier solve?

Send the application, current issue and target market. We can start with an engineering discussion.

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