The new front of vehicles allowing brand personalization and automated driving

charging

Electric vehicles (EVs) offer unique design opportunities for the front vehicle signature, now a central brand face without the need for classic engine cooling. Our front phygital shield, integrating sensors and lighting, respects appearances in both day and night, blending design with safety functions like protecting parking assistants and automatic distance control systems. Additionally, optional heating ensures reliable performance in bad weather, crucial for autonomous driving.

Highly attractive day and night appearance
High-performing lighting functions
Ready for automated driving
Integrated heating

Key features

Front phygital shield

New possibilities for front face design of your cars

Introducing the Front Phygital Shield (FPS) a revolutionary approach to automotive front face design. Engineered to enhance aesthetic appeal both during the day and at night, FPS offers a highly attractive appearance. Our in-house capabilities enable unparalleled design flexibility, providing a wide range of surface treatments to suit diverse styling preferences.

Sensor

Inbuilt light and secured sensor functions inside the shield

The Front Phygital Shield (FPS) integrates high-performing light functions, ensuring compliance with legal lighting standards while offering ample space for multiple sensors and lighting systems. Its design prioritizes versatility and functional reliability, especially in adverse weather conditions. The integrated heating system within the FPS secures sensor functionality, maintaining performance and accuracy despite challenging external elements.

FPS

Plug & play assembly - up to 8 layers assembled at once

The Front Phygital Shield (FPS) epitomizes production efficiency, showcasing the ability to assemble up to eight layers in a single step. This one-piece construction method not only exemplifies our mastery in merging plastic modeling, electronic integration, and lighting design, but also significantly streamlines the production process. By integrating up to eight layers simultaneously, the FPS allows for a reduction of up to 50% in assembly steps during production.

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Dynamic display for enhanced interactivity with the car

The FPS allows to create scenario for dynamic display according to the actions carried-out by the driver. It can “welcome” the driver to its arrival, inform charging status or display tailored information.

Technical specificities

Our front phygital shield features technical specificities across five key areas: modularity for versatile design, advanced lighting integration, comprehensive sensor systems, efficient heating mechanisms, and distinctive styling options. This cohesive approach ensures optimal functionality and full personalization.

Modularity

Multifunctional module to be integrated in the vehicle front. Lighting, sensor, heating and styling options can be combined considering customer-specific legal and technical requirements

Lighting

Legal functions like position and daytime running light as well as turn indicator can be realized with static or dynamic illumination. Surface, contour, logo/ radome illumination or a combination of them is possible using different optical systems.

Sensors

Integration of radar and LIDAR, ultrasonic and camera sensors possible.

Heating

Realized as foil with heating wires. Positioned in front of the radar sensor and thus only necessary in combination with radar sensor.

Styling

Body color or different styling appearance realized by film-insert molding (FIM). Implementation of metallic appearance and/or styling structures possible. Metallic appearance can be designed in the way that light shines trough the chrome application (achieving up to 30% light transmission)
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Key figures

140
More than 140 custom designs, showcasing versatility and customization capabilities.
8
Up to eight layers, some sustainable, for technical complexity and environmental mindfulness.
50%
Up to 50% fewer steps in assembly, enhancing efficiency and streamlining production.

The front phygital shield is a step forward in sustainable automotive design

Comprising up to eight layers, it includes materials that are environmentally conscious, such as recycled plastics, aligning with eco-friendly initiatives. This approach not only enhances the technical efficiency of the product but also demonstrates a commitment to reducing environmental impact, marking a significant stride in sustainable innovation within the automotive industry.

An innovation resulting from extensive research in lighting, sensor integration, and the modeling of car front faces.

Yves Andres
Managing Director Lighting at FORVIA HELLA

“Our front phygital shields align with key trends in mobility, especially electromobility and automated driving. They offer new design possibilities for electric vehicles' fronts, becoming a style-defining feature for differentiation in the market. Additionally, they are crucial for automated driving, integrating multiple sensors while ensuring their protection and functionality. Our shields provide a comprehensive system, addressing both aesthetic and technical needs in modern vehicles.”

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