A new automotive demonstrator integrates a blind spot warning light directly into the moulded trim of a vehicle’s A-pillar. The solution combines a flexible copper-clad aluminium circuit from DP Patterning, a moulded interior component from Artifex Systems and ICs and LEDs from ams OSRAM.
Integrating lighting into a curved, three-dimensional interior component places high demands on materials, manufacturing processes and component design. The demonstrator shows how thin, flexible circuits can support the integration of optical warning functions directly into automotive surfaces. It also creates a basis for further development toward an industrialized solution that could form part of a broader Tier 1 automotive offering.
The flexible circuit is manufactured using DP Patterning’s patented Dry Phase Patterning process. Dry Phase Patterning is a dry, roll-to-roll mechanical process that patterns solid metal foils, offering an alternative to conventional chemical etching. Using aluminium reduces material costs compared with silver-based alternatives.
Artifex Systems, a Tata AutoComp Systems company, initiated the project to explore the integration of electronic functions into moulded automotive components. DP Patterning patterns the circuit on laminate supplied by a Swedish manufacturer, while ams OSRAM provides the LEDs, the ICs and the board design. The project builds on a collaboration between DP Patterning and ams OSRAM in vehicle lighting that began in 2025.
“The hardest thing for a new manufacturing technology is not making it work. It is getting customers to trust it in production. A light built into a car pillar is a demanding application, and we have built it with almost the whole chain in Sweden. That gives companies with simpler applications a good reason to trust us. European automotive is under pressure, and this shows that new technology can make local production competitive," says Erik Berggren, Business Development Manager, DP Patterning.
Connecting integrated lighting to intelligent vehicle networks
A potential next development step is to combine the integrated lighting concept with the Open System Protocol, or OSP, developed by ams OSRAM. OSP is an open, license-free communication protocol designed for dynamic lighting applications and the integration of sensors and actuators. It can individually address more than 1,000 devices in a chain and supports functions including self-addressing and self-diagnosis.
In automotive architectures, OSP can provide the “last-mile” connection between intelligent lighting elements, sensors or actuators and higher-level vehicle networks. It can be integrated into a 10BASE-T1S zone architecture via a gateway, supporting the development of smart surfaces and dynamic lighting functions for decoration, warnings and communication.
For the A-pillar concept, this creates the perspective of developing a single warning light into a networked, addressable lighting function that can interact with the vehicle’s electronics. In combination with flexible circuitry and integration into moulded components, OSP could therefore support the development of a more comprehensive system-level solution for future Tier 1 applications.
“Lighting functions are increasingly becoming an integral part of vehicle surfaces rather than remaining separate modules. This demonstrator shows how compact LEDs can be integrated into a moulded interior component using flexible circuitry. In a future development stage, the Open System Protocol could provide the communication layer for connecting addressable lighting functions, sensors and actuators within an intelligent surface,” says Andrea Maria Saraceno, Marketing Manager at ams OSRAM.
From component demonstrator to integrated automotive solution
The next development stage will focus on translating the demonstrator concept into a scalable solution aligned with automotive integration and industrialization requirements. By combining lighting technology, flexible electronics, moulded interior components and, potentially, open communication technology, the partners aim to establish the technical basis for a more integrated Tier 1 proposition.
The Open System Protocol provides an open and license-free foundation for this development. Its base protocol is publicly available, while the application layer remains open for manufacturer-specific innovation and differentiation. Relevant driver products for this development path include the AS1163 Stand-Alone Intelligent Driver presented by ams OSRAM for dynamic automotive lighting applications. The AS1163 connects RGB, white and monochrome LEDs to an OSP network and can also connect sensors and actuators through an I²C interface. These products provide options for future development rather than components confirmed as integrated into the current demonstrator.
(Photo credit: ams OSRAM)
TrendForce 2026 Global Automotive LED Market- Lighting and Display Product Trend
Release Date:
1. PDF (160 Pages)- 30 June 2026
2. EXCEL- 30 June 2026 and 31 December 2026
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