Automotive Connector Failure, Safety Hazard
Industrial CT scanning is the ideal method for investigating points of failure within complex products like automotive headlights because it provides a non-destructive, 3D view of enclosed structures. We can easily evaluate welds, seals, wiring, lenses, adhesive bonds, and connector fitments without disassembly. By visualizing the root cause internally, manufacturers can improve design, assembly processes, and quality control while preserving the original part.
For litigation purposes, artifact preservation is not just preferred, but often required. The original condition of the part holds the truth about the failure’s cause. Any physical alteration, such as cutting, prying, or sectioning, can destroy or distort critical evidence, including microcracks or delicate connector interfaces that may already be partially separated or on the verge of complete disconnection.
The below CT slice image shows an electrical connection that is not fully seated, leading to intermittent contact whenever the pin on the left is disturbed. Intermittent or failed electrical contact can cause the headlamp to flicker, dim, or fail completely while driving, reducing visibility for the driver or making the vehicle less visible to others.
Large volume, high resolution CT scanning is useful for evaluating complex assemblies. Characteristics like dimensional measurement, fitment and seal evaluations, general inspection for FOD, and confirmation of components within sealed products are common use cases.
