ZKW Group

The ZKW Group has entered a cooperation with LG Vehicle Solutions and LG Soft India in order to utilize the synergies and expertise of LG’s software division. LG Electronics employs nearly 1,100 specialized experts in India who develop software for a wide range of applications – including automotive. The first joint projects are scheduled to start in October 2024. The aim of the collaboration is to develop software for premium lighting systems and intelligent lighting functions in order to further increase road safety. “The synergies with LG Soft India open up a great opportunity for ZKW to develop robust software of the highest quality for our customers together with the highly qualified specialists on site. This is an important step towards the Software Defined Vehicle,” says ZKW CEO Dr Wilhelm Steger.

Software plays a central role in modern automobiles. ZKW is now taking the next step to support the transition to software defined vehicle architectures. As part of the LG Group, the Wieselburg-based lighting system specialist is cooperating with LG Soft India in Bengaluru, one of the largest global research and development center of LG Electronics. The aim is to develop and manufacture high-quality products with high quality software contents. “This cooperation enables us to drive forward the development of new products for our international markets and open up new customer segments together with LG,” explains Dr Steger.

Vehicle lighting of the future​

Software is a key component of ZKW’s current innovations – such as the intelligent and adaptive front-lighting systems with highly complex algorithms behind. Animated rear lights also rely on software-based electronics that enable a wide range of functions and control options. Together with LG Soft India, platform developments for new products and technologies are now to be driven forward. “With the start of this close collaboration we will add valuable competencies to our international product development network as well as we support further innovation steps like scene-based lighting or the integration of AI-technologies”, says Udo Hornfeck, CTO of ZKW Group GmbH.

About LG Soft India​

LG Soft India, based in Bengaluru, is the innovation arm of LG Electronics and the company’s one of largest Global RD center outside Korea. Since its establishment in 1996, the company has become a trusted partner for customers worldwide, focusing on innovative technology areas such as Home Appliance Air Solution, Home Entertainment, Vehicle component Solutions, Business Solutions, webOS and Artificial Intelligence. With nearly 1,100 engineers, it is one of LG Electronics’ most important innovation centers. LGSI serves customers such as Mercedes Benz, General Motors, Toyota, Porsche, BMW, VW, Renault Nissan, JLR, Hyundai with solutions in automotive, webOS platform, and other fields.

About LG Vehicle component Solutions​

In 2023, LG Vehicle component Solutions Company achieved annual sales of the equivalent of 6.8 billion euros. The aim is to drive external growth, further expand expertise in the area of vehicle infotainment and utilize know-how from the areas of household appliances and IT. In addition, the e-Powertrain division is to be further developed and production sites overseas are to be strengthened.

The ZKW Group has entered a cooperation with LG Vehicle Solutions and LG Soft India in order to utilize the synergies and expertise of LG's software division. LG Electronics employs nearly 1,100 specialized experts in India who develop software for a wide range of applications – including automotive. The first joint projects are scheduled to start in October 2024. The aim of the collaboration is to develop software for premium lighting systems and intelligent lighting functions in order to further increase road safety. "The synergies with LG Soft India open up a great opportunity for ZKW to develop robust software of the highest quality for our customers together with the highly qualified specialists on site. This is an important step towards the Software Defined Vehicle," says ZKW CEO Dr Wilhelm Steger.

Software plays a central role in modern automobiles. ZKW is now taking the next step to support the transition to software defined vehicle architectures. As part of the LG Group, the Wieselburg-based lighting system specialist is cooperating with LG Soft India in Bengaluru, one of the largest global research and development center of LG Electronics. The aim is to develop and manufacture high-quality products with high quality software contents. "This cooperation enables us to drive forward the development of new products for our international markets and open up new customer segments together with LG," explains Dr Steger.

Vehicle lighting of the future​

Software is a key component of ZKW's current innovations – such as the intelligent and adaptive front-lighting systems with highly complex algorithms behind. Animated rear lights also rely on software-based electronics that enable a wide range of functions and control options. Together with LG Soft India, platform developments for new products and technologies are now to be driven forward. "With the start of this close collaboration we will add valuable competencies to our international product development network as well as we support further innovation steps like scene-based lighting or the integration of AI-technologies", says Udo Hornfeck, CTO of ZKW Group GmbH.

About LG Soft India​

LG Soft India, based in Bengaluru, is the innovation arm of LG Electronics and the company's one of largest Global RD center outside Korea. Since its establishment in 1996, the company has become a trusted partner for customers worldwide, focusing on innovative technology areas such as Home Appliance Air Solution, Home Entertainment, Vehicle component Solutions, Business Solutions, webOS and Artificial Intelligence. With nearly 1,100 engineers, it is one of LG Electronics' most important innovation centers. LGSI serves customers such as Mercedes Benz, General Motors, Toyota, Porsche, BMW, VW, Renault Nissan, JLR, Hyundai with solutions in automotive, webOS platform, and other fields.

About LG Vehicle component Solutions​

In 2023, LG Vehicle component Solutions Company achieved annual sales of the equivalent of 6.8 billion euros. The aim is to drive external growth, further expand expertise in the area of vehicle infotainment and utilize know-how from the areas of household appliances and IT. In addition, the e-Powertrain division is to be further developed and production sites overseas are to be strengthened.

All ZKW products to be designed according to Net Zero principles by 2038 – focus on environmentally friendly and resource-conserving production and employees. In its current Sustainability Report for the 2023 financial year, the ZKW Group highlights its most important sustainability topics. The Group, which develops and produces high-quality lighting and electronic systems for the global automotive industry at twelve locations in eight countries, was able to achieve record sales of around 1.5 billion euros in 2023 despite difficult conditions. Sustainable management is an important concern for the ZKW Group and its customers. The aim is to decarbonize the entire production process by 2025 and to promote environmentally friendly production by saving energy, avoiding waste and switching to green electricity. By 2038, net-zero targets are to be implemented for all ZKW products along the entire value chain and thus climate-friendly production. "Sustainably profitable growth requires responsible action. With our sustainability strategy, we are taking a consistent approach and assuming responsibility for people and the environment," says Dr. Steger.

The current sustainability report shows the goals and results in the most important areas of action. In terms of climate protection, ZKW focuses on energy-efficient production processes and the use of renewable energies at its locations and in the upstream value chain. In order to reduce the consumption of resources in production, sustainable raw materials and the circular economy are increasingly being used. The company offers its employees a healthy and safe working environment. In addition, ZKW promotes training and further education, advocates fair working conditions and supports social and ecological projects. For its commitment, the ZKW Group was recently awarded the ISO 14001:2015 environmental management system certificate by Quality Austria. "Sustainable action has always been important to us. This is linked to our goal of making mobility safer through our products and thus ensuring greater safety on the roads," explains Dr. Wilhelm Steger, CEO of the ZKW Group.

Fewer emissions through energy-efficient production​

The aim is to develop and produce products more efficiently and sustainably. ZKW uses energy-efficient production machines that reduce CO2 emissions. Since 2022, production at the Wieselburg, Wiener Neustadt and Dalian (CN) sites has been powered exclusively by green electricity, and from 2023 in Mexico and Slovakia by 50 percent. By 2025, only green electricity is to be used at all production sites. The plant in Slovakia was built using particularly energy-efficient and environmentally friendly construction methods. ZKW also implemented high sustainability standards for the plant expansion in Mexico in 2023. In summer 2023, the first photovoltaic system went into operation at the Chinese plant in Dalian. It is expected to cover around eight percent of annual electricity consumption and thus avoid potential CO2 emissions of up to 2,250 tons. In the area of waste management, the volume of residual waste was reduced in Wieselburg thanks to the commissioning of baling presses to separate waste by type. In Dalian, adhesive waste was reduced through improvement measures. At the Silao plant, waste management was optimized through on-site separation and the sale of metal components. "Flexible and ultra-modern production sites enable a customer-oriented product and technology offering at the highest quality level, which also takes into account the relevant environmental and occupational safety aspects," says Dr. Steger.

Research and development for a sustainable future​

A key part of the strategy is continuous research and further development of the lighting systems in order to achieve sustainable end products. These further developments are presented on an ongoing basis at customer meetings, tech shows and trade fairs, where feedback is obtained and further adapted. A major focus is on research into plastics, which are among the most important materials in production at ZKW. ZKW has been conducting intensive research into alternative solutions in all product categories since 2022. Research projects such as "SustMat4carLight" are intended to enable significant CO2 savings – for example through the increased use of recyclates, biogenic and mixed raw materials. In another research project, ZKW is investigating biodegradable substrates that can be used as a basis for printed circuit boards. This should enable CO2 reductions of up to 60 percent. "We are driving innovation with initiatives for green electronics, the development of efficient product modules and research into more sustainable materials in the supply chain," says Dr. Steger.

Focus on employees​

Around 10,000 employees work at the ZKW Group locations in Austria, the Czech Republic, Slovakia, India, China, the USA and Mexico. Targeted occupational health and safety measures (including ISO 45001:2018 certification, instruction, protective equipment, safety newsletters, public displays and the myZKW app) have reduced accidents at work by around 71% since 2017. At ZKW, all employees are trained according to their position and personality in our own Competence Training Center – from apprentices to managers. The working-from-home policy allows employees to work from home for up to eight days a month. In addition, ZKW ensures the well-being of its employees with company restaurants at almost all locations, fitness and prevention programs and a crèche.

Diversity as a competitive advantage​

Diversity is seen as an advantage and an investment in the future at ZKW. As a global employer, the company unites 54 nationalities under one corporate roof, including more than 14 at the headquarters in Austria. At the heart of the ZKW Diversity Strategy is a 5-point plan designed to raise awareness of diversity inclusion, women in leadership, people with disabilities, intercultural diversity and work-life balance. "Appreciation for our employees and customers is at the heart of everything we do. We are aware of our social responsibility and take it seriously," says Dr. Steger.

Audi’s new SUV flagship relies on premium technology and clear design. The HD Matrix LED headlights from ZKW, developed jointly with Audi, are a perfect match. The premium lighting system offers digital daytime running lights with selectable, digital light signatures that allow the headlights to be customized. An optional additional laser high beam provides even more range. The high-tech headlamp also has a dynamic indicator light and a blue ambient light for the laser. Development and production of the premium lighting system are based in Wieselburg. “The project demonstrates our expertise in the development of high-end technologies for headlights. Innovative solutions such as the new digital daytime running light signatures are pioneering on the market,” says Dr. Wilhelm Steger, CEO of the ZKW Group.

The Q8 comes with LED headlights as standard. As an extra, there are HD Matrix LED headlights with 24 LEDs and one high-performance laser diode per headlight. This allows the road to be optimally illuminated and oncoming traffic and vehicles in front to be selectively masked, thereby increasing road safety. As a special innovation, four different digital daytime running light signatures can be selected. The basis for this is a daytime running light cover with a double microstructure, which ZKW developed together with the Audi development team.

Laser for even more extra high beam power

In the top version of the Q8 headlamp, a high-performance laser diode illuminates the darkness. The laser as an additional high beam is activated from a speed of 70 km/h and significantly increases the range of the high beam. The system is based on reflector technology and helps to significantly increase not only road illumination but also safety. The laser high beam is visually recognizable by the so-called ambient light – a blue LED light guide integrated in the headlamp.

Premium lighting technology for luxury-class SUVs

The development of the new daytime running light signatures, which was carried out jointly with Audi, was integrated into the vehicle in a sophisticated manner.

ZKW uses the new production method, the Cobot system, in the production of the Q8 headlamp. The assembly personnel work together with a collaborative robot, which pre-positions the daytime running light components in preparation for subsequent manual completion. The daytime running light unit is also prefabricated on a separate assembly line in order to meet the high quality requirements and complex assembly process.

The narrow front and rear lights, which were developed by ZKW in Wieselburg, are very unusual. At the front, the dark, high-resolution LED headlamps blend harmoniously into the front of the BMW XM. At the rear of the powerful SUV, BMW relies on all-round, narrow full LED lamps with separate controls. "Alongside the BMW X7, the BMW XM is the first rear lamp project with the BMW Group. We are proud to be able to incorporate our innovative lighting solutions into these premium models," says Dr. Wilhelm Steger, CEO of the ZKW Group.

This unique project presented ZKW's engineers with major challenges. Due to the low height of the headlamp, a special light guide concept had to be developed. "The development of the headlamp presented the BMW design team and ZKW with a particular challenge. It had to be as narrow as possible in order to emphasize the unique design of the vehicle," explains Wolfgang Zeidlhofer, project manager at ZKW. ZKW developed a split front light with two high-resolution LED modules that integrate headlamps with low beam and high beam as well as daytime running lamps with LED light guides for position lights, direction indicators and sidemarkers (for the US version).

Highest standards in design and production

When developing the front and rear lamps for the BMW XM, not only was technical perfection required in very small installation spaces, but also maximum dimensional accuracy and small gaps. The adjustment system for the components in the rear lamps is unique, allowing a particularly small gap to be achieved between the different light functions. However, the small installation space in the bumper for the headlamps also presented the ZKW development team in Wieselburg with a major challenge, which was successfully overcome with a space-saving design. The headlamps of the BMW XM are produced in various international ZKW plants.

The lighting systems specialist ZKW is delighted to have received another prestigious award. On February 28, the Wieselburg-based company was presented with the “Lighting Star Award” for “Best front lighting design” by the industry association DVN (Driving Vision News) in Munich. The award recognizes the innovative front lighting design that ZKW developed for the animated “Thorhammer” LED headlights of the Volvo EX90. When switching to high beam, the daytime running lights split upwards and downwards to reveal the main headlights. “We are particularly pleased about the award, which rewards the elaborate development of this unique, brand-typical front lighting,” explains Dr. Wilhelm Steger, CEO of the ZKW Group.

As a community of industry experts, DVN organizes regular workshops and serves as a platform for its members from the automotive industry to exchange information. The DVN Award Ceremony, at which the ZKW was honored, was the highlight of the first DVN Workshop 2024. Among the numerous specialist presentations, Udo Hornfeck, CTO of the ZKW Group, spoke about “Design and lighting in the Volvo EX90”. At the CEO Talk on the topic of “The changing automotive industry”, ZKW CEO Wilhelm Steger discussed strategies for the future, sustainability, software-defined vehicles, artificial intelligence and much more with renowned representatives from other automotive suppliers. Gerald Böhm, GSM Advanced Technology and Technology Relationship Management ZKW Group, provided exciting insights into the future of vehicle lighting in his presentation on “Display – technical possibilities and outlook”.

Excellent lighting design

For the award-winning headlights of the Volvo EX90, ZKW uses a digital segment light module that combines matrix high beam and low beam. The system combines daytime running light, position light and indicator light in the particularly compact form of the striking “Thorhammer” design. The innovative kinematics enable the daytime running lights to “wink”: when the vehicle is unlocked, the individual headlamp elements flash one after the other before opening up and releasing the high beam with a blinking effect. The smart headlamp was developed at the ZKW site in Wieselburg and is manufactured at ZKW in Silao/Mexico and Dalian/China. “Our development department was able to meet the brand’s high design standards with a great deal of commitment,” says Dr. Steger.

About DVN Lighting

DVN Lighting is a community of industry experts who regularly exchange ideas. The aim is to consolidate and analyze information in order to support DVN Lighting members. “DrivingVisionNews” is the trade magazine for all aspects of vehicle lighting, vision and driver assistance. The DVN in Munich was very popular with 450 visitors, 100 companies, 30 exhibitors and more than 25 OEMs.

At this year's Consumer Electronics Show, which takes place from January 9-13 in Las Vegas, ZKW and LG will be showcasing their innovations in the areas of intelligent vehicle lighting and infotainment. The highlight is the LG concept car, which is equipped with high-resolution microZ-LED headlights from ZKW. This should make cinema-like "drive-in theater" projections possible in the future. ZKW will also be presenting the latest innovations such as the intelligent "Illuminated Panel" and an illuminated bumper (together with Rehau), animated rear lights, sustainable headlights as well as the new headlight for the Volvo EX90 with the moving "Thorhammer" and GM Chevy Silverado headlights for the important American vehicle market. "With our locations in Silao/Mexico and Troy/Michigan, we offer customers in the USMCA economic area innovative lighting systems that can interact with other road users and increase driving safety," explains Wilhelm Steger, CEO of the ZKW Group.

In the CES Public Area, the LG Concept Car offers visitors an insight into the future of automotive entertainment. The ZKW microZ headlight modules integrated into the front of the show car demonstrate how animated projections can be created in the future using intelligent front lighting. The projector function of the headlights generates a 100-inch image that can be used to display a wide range of entertainment content based on OTT communication via the Internet (e.g. Netflix), transforming the car into a mobile cinema experience. "With the 'Digital Lighting Experience' vision and strategy, we are taking our portfolio to a new level together with LG," explains Steger.

Intelligent vehicle front & illuminated front panels
ZKW will also be showcasing its latest product innovations in the CES Private Area. Highlights include the illuminated multi-colored front grille "Panel" and, for the first time, an illuminated bumper "Bumper", which were developed in cooperation with REHAU Automotive. ZKW will use demonstrators to show how modern lighting, electronics and sensor systems can be integrated into vehicle fronts. The concept can be used, for example, to redesign the front of electric vehicles that no longer require a radiator as a smart design object with lighting, logo, sensor and heating functions. In the future, intelligent vehicle fronts and other series products are to be developed that interact with other road users and can thus increase road safety.

Smart lighting systems
ZKW's latest innovations include the high-tech headlights of the Volvo EX90. They are based on digital HD LED modules with a resolution of over 1.3 million pixels, which dynamically adapt the light to the traffic situation and precisely block out other road users. As a unique feature, the premium headlights can swivel the daytime running lights up and down in the typical Volvo hammer shape, thus revealing the main light modules - a design innovation that also helps to save installation space. As a new development, ZKW, in cooperation with OSRAM, is presenting innovative rear light modules in which transparent LEDs are laminated onto a transparent carrier substrate. The result is an animated surface that can display tail lights, indicators, brake lights and illuminated logos. The new headlamp of the GM Chevy Silverado, which enables an illuminated animation of the charge indicator, will also be on display at CES.

Sustainable production
ZKW aims to make its global production CO2-neutral by 2025 and all products by 2038. This goal is to be achieved by saving energy, avoiding waste and switching to green electricity. At CES, the lighting systems specialist will be demonstrating how sustainable lighting can be achieved through optimized materials and processes. As part of the "SusMat4CarLight" project, ZKW is working with partners to research recyclable materials for future lighting systems, including polymers based on renewable raw materials. "Our sustainability strategy makes it possible to reduce CO2 emissions from production and products by 60 percent. The aim is to develop and produce more efficiently and sustainably. Sustainable management is a key concern for both the ZKW Group and its customers," says Steger.

WIESELBURG, Austria, Oct. 5, 2023 -- The Wieselburg-based automotive lighting specialist equips the brand new Volvo EX90 electric SUV with high-quality LED headlights in unique design. The basis are digital HD light modules with over 1.3 million pixel resolution, which create a precisely controllable light image on the road. The high-tech light adapts dynamically to the traffic and precisely blends out other road users. The system thus contributes to high safety for drivers, passers-by and animals. As a unique feature, the high-quality LED headlights can wink the daytime running lights shine in the hammer-shaped design typical of this Swedish brand. When switched to high beam, the daytime running light splits up and down to reveal the main headlamp. "The unique front lighting, which is distinctive for the brand, combines exceptional design with innovative lighting technology that actively contributes to high road safety," explains Dr Wilhelm Steger, CEO of the ZKW Group.

The new SUV's headlights are an evolution of the distinctive headlight design that the brand first introduced on the second-generation XC90 in 2015. The LED light elements of the daytime running lights form the hammer-shaped design, with the head divided into six light segments, while the stem is formed by ten other elements. If you switch to main light, the hammer splits horizontally and the main headlight becomes visible. The movement not only serves to switch from daytime running light to main light, but also underscores the vehicle's start sequence with a "wink" of the headlights. "This animated light function is unique and only available from this manufacturer," explains Dr Steger.

High-resolution LED pixel light
As the basis for the headlamp, ZKW uses a "Segment Light" light module that combines matrix high beam and low beam. The signal light system combines daytime running light, position light and indicator light in the particularly compact form of the striking design. The daytime running light, which is movable thanks to the innovative kinematics, gives the brand new SUV a unique appearance. When the vehicle is unlocked, the individual headlight elements flash one after the other before flipping open to reveal the high beam with a flashing effect. The smart headlight was developed at the ZKW site in Wieselburg, and is manufactured at ZKW in Silao/Mexico and Dalian/China. "By using recycled plastic granulates and aluminum made from 40 percent recycled raw materials, we are also making a major contribution to sustainability," says Dr Steger.

High demands on design
Various requirements had to be taken into account in the development of the high-tech headlamp. On the one hand, the system had to withstand at least 500,000 opening and closing cycles under all environmental influences. Furthermore, the horizontal part of the daytime running light must have reached its end position within 500 milliseconds in order to release the main light functions. In addition, a low weight of the moving parts was required with simultaneous homogeneity of the daytime running light. "Our development department was able to meet the brands high design demands with a lot of commitment," says Dr Steger.

About ZKW
The ZKW Group is the specialist for innovative premium lighting systems and electronics. As a system supplier, ZKW is a global partner to the automotive industry. The group develops and produces products based on our motto of "Bright Minds, Bright Lights," combining bright minds with modern production technologies to produce complex premium lighting and electronic modules for international automotive manufacturers.

Our top products include powerful and cost-efficient complete LED systems. The ZKW Group has a total of twelve locations worldwide, with intelligently networked development and production. In 2022, the Group employed around 10,000 workers and generated total revenues of 1.4 billion euros.

In accordance with the corporate vision "Ground-breaking premium lighting and electronic systems from ZKW for all mobility concepts of the global automotive industry", the company's primary goal is to produce top-quality high-tech products and to promote the development of innovative holistic lighting systems.
With our discoveries and inventions, the ZKW corporate group makes vehicles more desirable, more unique, safer, and more energy efficient.

Our 360 degree product portfolio includes headlamps and fog lamps, rear lamps, flashers, interior and license plate lamps as well as electronic modules. Major automotive manufacturers trust their brands to innovative products from ZKW. We are proud of our customers like BMW (BMW, Rolls Royce), DAIMLER (MERCEDES-BENZ Cars and Trucks), FORD (Lincoln, Ford), GEELY (Volvo, Polestar, Lynk & Co, Geely), GENERAL MOTORS (Buick, Chevrolet, Cadillac), Hyundai/Kia, JLR (Jaguar, Land Rover), Stellantis (Opel, Citroen), RENAULT/NISSAN (Infiniti, Alpine), VGTT (Volvo Trucks, MACK) and VW (Porsche, Audi, Lamborghini, Bentley, Skoda, Seat/Cupra, VW, VW Commercial Vehicles, MAN, Scania).

With intelligent lighting systems and innovative styling, ZKW is shaping the look and character of vehicles worldwide.