What Makes Our Process Different

We follow an OEM-grade replacement system that meets Norgelys Fitment Approval. A standard that defines precision, safety, and optical performance.

Unlike general workshops that rely on heat guns and unverified parts, our technicians adhere to the same procedures used in European lighting factories.
Every process is designed for dimensional precision, optical clarity, and long-term reliability - not shortcuts.

1️⃣ We Don’t Use Low Quality Lenses

Most replacement lenses on the market are low-cost acrylic or recycled-grade polycarbonate that yellow, crack, or distort under heat.
We exclusively use Norgelys manufactured Lexan™ HP92AF optical polycarbonate lenses, engineered in Norway and produced under ISO-certified optical standards.

  • UV-cured Polysiloxane hardcoat for superior scratch resistance

  • 92 % optical transmission matching OEM light dispersion

  • Certified resistance to yellowing, fogging, and thermal deformation

Every lens we install is laser-etched and batch-tracked by Norgelys, ensuring full authenticity and traceability.

2️⃣ Certified Technicians – Norgelys Fitment Approved

All our technicians are Norgelys Fitment Approved and have undergone hands-on training in Norway directly under Norgelys engineers.
Their training covers complete headlight disassembly, polycarbonate handling, adhesive chemistry, and optical sealing to OEM specifications.

We perform every stage of restoration using precision tools and separation equipment supplied by NL, guaranteeing consistent results and full compatibility with NL components.

Our facility operates within a closed environment, temperature controlled clean bay  the only one of its kind in South Africa, ensuring every restoration meets OEM-level precision.

Each certified technician is qualified in:

  • Polycarbonate handling and temperature control

  • Optical resealing and vacuum integrity testing

  • Adhesive chemistry (Permaseal, Butyl, Hybrid systems)

  • Quality inspection under polarized lighting

3️⃣ Controlled Thermal Separation

Instead of heat guns or ovens, we use digitally regulated thermal chambers that maintain a precise temperature curve between 100 °C and 115 °C.
This ensures the factory adhesive softens evenly without warping the reflector housing or melting internal components.

Improper heating methods such as direct heat-gun application can raise localized temperatures above 250 °C — enough to degrade LED driver boards, weaken solder joints, and shorten LED lifespan by up to 50 %.
Our controlled process prevents these failures entirely by keeping thermal exposure uniform and within safe OEM tolerances.

Each headlight follows a unique temperature profile depending on its original adhesive composition — a standard OEM practice.

4️⃣ Ultrasonic and Mechanical Delamination

Our proprietary delamination tools are also Norgelys supplied and ultrasonic edge resonators separate lenses without damaging sealing channels.
This preserves housing geometry and eliminates micro-cracks that can lead to leaks a problem common with manual or blade-based separation.

5️⃣ Interior Cleaning and Decontamination

Once opened, the entire internal housing is cleaned under negative pressure filtration to remove static dust and silicone haze.
We perform full reflector and lens cleaning as well as ionized air drying to prevent condensation or fogging.

Every headlight that leaves our facility is spotless inside and out.

6️⃣ Precision Resealing and Final Testing

Reassembly is performed using Morimoto OEM butyl sealant, applied and compressed under controlled temperature and pressure for a perfect reseal.
Each headlight is vacuum tested and undergoes full optical validation under polarized inspection lighting.

We simulate real world temperature cycles (0 °C → 50 °C) to ensure condensation resistance and pressure stability before shipment.

Why Choose Us

We are not a repair shop — we are an engineering facility.
Our process is complex because it’s done properly.
From Norgelys trained and Fitment Approved technicians to Norgelys supplied tooling and European-manufactured materials, every step is designed to restore your headlights to true OEM condition — with no melted edges, no fogging, and no shortcuts.

If it doesn’t meet factory standard, it doesn’t leave our facility.