TRIPLE-R LIGHTS | Factory Tour

Not all lights are built the same, and certainly not the same as Triple-R Lights! In this video founder – Ben Russell-Smith walks you through our new 60,000 sq ft head office and manufacturing facility in Harlow, UK.

Occupying the site since August 2023, the quality systems and processes in place, whether in regards our design, engineering, or manufacturing functions, means the performance and reliability of our high performance LED lighting solutions is assured.

Welcome to Triple R lights I’m here at the headquarters and Manufacturing uh facility in harow England trip R lights is part of the laser lamps group I’m going to give you a tour of our state-of-the-art facilities we’ll see how the lights get made let’s go Triple R lights has got a distribution

Center in Phoenix Arizona and we’ve got a team there aimed at helping you our customers with the uh products but all of our lights are manufactured here in the UK laser lamps as a company has had a history dating back to 2010 from those very early days our products were

Recognized in the Power Sports World as the leaders and we used the very best components we could and we built them in a way that ensured when they were put back toback against competitive products ours would come out on top we’ve seen those products being adopted uh through

A number of different areas of Motorsport and Power Sports from World Rally through to leemon uh hyper car GT3 Dakar so in Phoenix Arizona we have that location we’ve got a local team but of course they get support here from the UK we’ve got in this office our sales and

Marketing team they Pride themselves on strong Partnerships with uh with power sports customers commercial customers and so on and we really use those relationships not just to enhance the uh the the product but actually we’re also innovating and coming up with Solutions based on feedback that we’re getting

From those customers through now into the engineering office so here in the engineering office this is where all of the clever stuff is done the design of our products from initial concept generation through to ensuring that it can be manufactured in an efficient way you’ll see that we’ve got

Grills on the wall these are uh grills for current production vehicles that we might scan in we’ll get the geometry of that Grill and then we’ll design brackets to accommodate the lights through now to electronics so Electronics is a very important part of our products the reliability and the

Performance of what we launch is absolutely critical the products have to be at the top level the performance has to be second to num and they’ve got to be wholly reliable all of our Tri R lights undergo a rigorous testing program before we launch so we’ve got a climate cycle

Where we can under undergo various uh thermal and humidity sweeps we’ve got salt spray testing and as well we’ve got solar load testing so we’re able to simulate uh the sun in Arizona um over a 5-year period uh before we bring a product to market in terms of validating the performance

Some of our us lights have a do and SAE approval uh so that means we have to ensure that when they’re tested they’re within certain prescribed limits according to US Federal lighting regulations so we do that here on site at our uh in-house uh light curtain we’re able to project the light against

A a wall and then we use software to translate that image into a driver’s eye view and we make sure within the uh regulation limits we’ve also got a 30 m light tunnel uh where we can verify um absolute intensity measure measurements and 30 m is quite a long way hi

Moving to the new facility has enabled us to bring inhouse some of those uh really critical processes that we used to need to rely on suppliers for vacuum metalizing of reflectors we use a very advanced process for that so unlike some of our competitors that might have a

Chroming process we use aluminium vapor deposition which has the highest reflectivity of a coating that you can uh you can buy we’re doing that process inhouse because it ensures that we meet the performance requirements of the product powder coating facility is brand new uh We’ve introduced a five-stage

Wash process and paint spraying to guarantee that the quality is exactly where we want it to be uh and of course corrosion performance is second to num so when building lights one of the first steps of course is to inspect the components that are coming in from our suppli

Quality is absolutely core to the laser lamps brand and of course in the US the tri R brand and by that every component that we purchase you know we’re inspecting the supplier and some of these suppliers we’ve got a relationship that dates back years so that we’ve got

A uh guaranteed condition of quality that we’re satisfied with uh and then once they’ve been approved for production they can start to be built into lights let’s go through and we’ll see the next step of the Process so some of the most critical products in the lamps are of course the components that we use on the circuit boards so we kit all of the components for the circuit boards here in house ready for PCB assembly we’ve got tens of thousands of lines of components and for

Kitting of the parts it’s a full-time job and we’re needing to always ensure that we’re using the right component for the right job to get the best performance out of the product we’ve got two large stacking machines these stacking machines enable us to keep all of the components and the pcb’s humidity

And temperature controlled we need that for ESD reliability so that means electrostatic discharge the storage system allows for a huge number of boards we’ve got a very wide range of products and all of it is here so once those circuit boards are assembled we can then begin the uh light

Building process so for tri R lights again all of our products are made here so that means plasma priming of the heat sink assembling the cable into the product we’re mounting the reflectors we’re doing the light up checks and then we’re bonding the lens into position so they’re dealing with very small circuit

Boards small reflectors and they have to mount it together in a very challenging uh way so they do a great job uh we often build in batches of 75 at a time and we’re producing about 400 lights per day and actually if you look at the way

That we manage the quality in the production area you’ll see that all of the operators are working with these uh tablets and the tablets are how they are guaranteeing that the assembly process is according to the instructions that are being defined by engineering so they’ll use those tablets all the way

Through the build and make sure that they get exactly the right level of uh detail on building the lights so building the lights isn’t the only thing of course after we’ve built them we have to test them we can see here the final light up check so we’ll

Illuminate All of the Lights uh in one go and this will occur after we’ve done the product leak test the leak testing process is one where every light that we manufacture gets submerged in our leak test tank and the operator will leave it in there for a minute 2 minutes before

Removing it and we do a final validation that there’s been no water Ingress so we’re here now in the final packing area so this is where we’ve got a lot of detailed work the product has to be right checking cleaning the product and this is our final chance to

Ensure that the product leaving the building is exactly how we want it when you open the box and receive your uh your light for the first Time okay so we’re here in the final uh Goods out area so all of the products are stored here we’ve got um a huge range that we keep inhouse here in the states of course with trip R lights we have our own facility there with a um

Warehouse and uh storage and a team there locally to support the market lot of care taken on the boxes going out the door and yeah generally speaking we’ve got 100 150 orders going out every day so I hope that’s giving you some insight into the way that we produce our Tri R

Lights here in England our facility here is absolutely at the top level the staff here uh strive to perform at their top level they’re passionate about what they do and the products need to be always at the top of their game the US in particular is an exciting prospect for

Us as we move forward we listen to what our customers want we have a local team there in Phoenix Arizona owner listening to the market and we’re ensuring that we’re engineering Solutions specifically for the US customers thanks for watching please do check out our social media and check out

Our website and watch this space for tri R lights in the Future