Reasons You Might Never Need to Replace an Entire Mercedes Headlight Again | Carscoops

      Mercedes is reinventing its manufacturing processes with repairable headlights and the use of recycled materials to minimize emissions and waste.

      In future headlight units, Mercedes will replace glue with screws. This change means that headlight lenses can be replaced without incurring the full cost of a new assembly. This initiative aligns with their goals for circular manufacturing and recyclability.

      While numerous automakers demonstrate innovation, few can match Mercedes' established track record in safety, comfort, and production excellence. The German automaker is now taking a more fundamental approach by replacing glue with screws in essential components, marking a return to simplicity.

      Under a new plan called Tomorrow XX, Mercedes is re-evaluating the assembly of certain parts. For instance, their headlights are anticipated to see a design overhaul. Currently, modern headlight assemblies mainly rely on glue as a bonding agent.

      Although it is technically feasible to disassemble these glued units, the complexity and difficulty of the process make it impractical for the average owner. As a result, these units often become disposable once a single component fails. Mercedes aims to enable the use of screws for assembly instead of glue, allowing for easier repairs.

      This seemingly simple change holds significant implications. If a headlight lens suffers damage from a stone chip, for instance, it could be unscrewed and replaced individually, eliminating the need for owners or insurers to purchase a complete adaptive LED assembly.

      Depending on the vehicle model and type of headlamp, replacement costs can fluctuate between approximately $500 to over $3,000 per unit, particularly for advanced Multibeam LED systems. This approach could substantially lower repair expenses and reduce waste. It's worth noting that U.S. regulations currently do not permit replaceable headlight lenses, but other countries may still benefit from this innovation.

      This return-to-basics philosophy extends to other areas, as Mercedes is investigating ways to create interior door panels that are easier to disassemble by substituting ultrasonic welding with reversible thermoplastic rivets. When a vehicle reaches the end of its lifecycle, these panels could be dematerialized rather than shredded entirely.

      Recycled components are already being integrated into production models. The forthcoming CLA-Class features a windshield washer tank made from 100% recycled polypropylene and bumpers composed of 25% recycled material.

      Additionally, Mercedes is experimenting with the use of recycled airbags for engine mounts, employing old tires for sound insulation, and creating synthetic leather partially from repurposed plastics. While these changes may seem minor individually, collectively, they could lead to significant long-term impacts.