This is a comprehensive 2025 MY Visor Assembly design analysis with a Wireless Vanity Mirror. The current Visor Assembly, as shown below, has been thoroughly evaluated for potential areas of improvement.
The current design, which has remained unchanged over the last few decades, has great potential for improvement. It’s crucial to ensure that the new Visor is designed to meet not just basic FMVSS requirements but also the evolving needs of our customers.
GM and Ford Visor Assemblies have been the standard in-market design for the last few decades, with minor changes to meet packaging or styling needs. The only other addition is the garage door opener, shown below. This functionality is now moving to the Center Console.
As a reference, a simple full-function visor that has been in production for a few decades has more than 40 components. The components briefly are Bracket L/R, Metal Tube Arm L/R, Elbow L/R, Connector, wire fixture, Terminal, Visor Exterior Harness, wire protector pipe, D-Ring, Carrier Tube, Rivet, Metal Frame Wire, Plastic Frame Plate-LH/RH, Frame Cap, Frame Cap, Carrier, Contact plate, Terminal insert in the carrier, Detent Spring, U-Detent Spring Support, spring, Detent Spring Support, contact ball, spring, Vanity Cover, Vanity cover hinge, Vanity Frame, Lens, Vanity Cover Bumpers, Mirror, Vanity Cover Spring, Inactive Switch, Active Switch, LED. Vanity Frame Harness, EPP Core (Vanity Side)-LH/RH, EPP Core (Back)-LH/RH, Visor Cover, Warning Label, Bracket Screw, Carrier/detent Lube, Vanity Cover Lube, and maybe others have been missed.
Again, Visor’s design has stayed the same over the last few decades, except for the Tesla Visor. However, the Tesla Visor’s cost is ten times that of the standard automotive Visor. The assembly component target must be ten in redesigning the Visor through innovation.
Design HMI’s target is to increase the Visor’s WOW effect and reduce cost in the bargain. If you take the critical purpose of the Visor is sun blockage without affecting visibility for 95% of the drivers – I’m not sure the current Visor meets that want.
2025 CY Visor Design: Below is the simple 2D Design for both Transparent and non-translucent Visors, which not only brings significant feature improvements but also promises substantial cost savings, enhancing the overall functionality and appeal of the Visor.
The Wireless Vanity Mirror Assembly location will be based on styling requirements.
Bill of Materials and Visor Cost Target: Below is the BOM target for the next generation Visor Assembly.
- Top D Ring / Visor Holder Body – two-piece assembly:
- Metal or PC-ABS Tube and Bracket:
- Spring and Misc Components for movement:
- PC-ABS 2.5mm thick Frame with Fabric-Arctic Visor Cover:
- Minor Assembly Components:
- Vanity Mirror PCBA with LED Lens.
- Mirror Assembly with frame & cover.
The total direct fully loaded cost target would be $5.50, and 25% overhead would be added for a total ex-factory cost of $6.85.
The design option involves a minor cost increase to replace the PC-ABS 2.5mm thick Frame with a Fabric-Arctic Visor Cover and a primary translucent Visor Assembly.
The cost of the translucency-adjustable high-end Visor Assembly still needs some work, but based on annual volumes, the target would be $20.00 to $35.00.
The above design showcases that feature innovation can sometimes require a cost increase. HMI assembly production tooling and assembly investment fully recover after a few years (say between 3 and 5); thus, the Integrator’s reluctance to upgrade the design. However, that results in lower product value as it has no WOW effect, which is common in the Automotive Eco-System as opposed to other industries. The innovation value proposition is ignored, resulting in reduced profitability. The OEM core target becomes only cost reduction to stabilize, not increase profitability.
For more information, email bbedi@designhmi.com.
Below is one potential with LC Film Operating Mode that is transparent when no voltage is developed by Smart Films International. Optional for independent working mode: Solar cell + Rechargeable battery with automatic or customer-controlled base.
Base Technical Specifications:
- VLT range: 30% to 1%
- Haze: ≤1%
- Visor Size: 400 by 170mm (Our capabilities cover a bigger LC film area if required)
- Film Thickness: 0.6mm
- Working temperature: -10℃~60℃
- Storage temperature: -40℃~85℃
- Operating Voltage 0-8VAC
- Power consumption: 5mA
- Response Time: ≤30ms
Current Sun Visor designs have TGW concerns and thus a low favorable rating for most. When the sun is low during sunrise and sunset the sun visors have a limited effect because the pair only can cover the superior part of the windshield. Current sun visors don’t have a height to allow protection against the sun’s rays. The other open issue related to drivers’ height – for low-height or tall drivers the current design sun visor may not be very effective. Upcoming panoramic translucent roof designs will make integrating current designs even more challenging.
One simple concept is an opaque sliding or folding extension mounted on the automotive sun visor. The 
extension can slide into the s un visor body and extend vertically at a 50 mm distance to protect the driver from the sun’s rays. The sun visor’s main body has two different parts and connecting them to move relative to each other it is possible to slide the entire sun visor in front as in the traditional manner and to slide variably his lower part to achieve good protection of the driver in the morning and evening dazzle. But I believe this concept will still be distracting for many people and more as on a long drive the position of the sun relative to your eyes moves. In addition, could block the forward vision of people based on their relative heights and seat position.
In the future, the visor will need to become smart yet at the same time improve the anti-glare function, and increase the size of the component to cover more, without reducing the driver’s visibility. increasing anti-glare effectiveness is critical to overcoming current limitations at certain times of the day, when the sun is very low, or for certain driver’s percentiles.
Design HMI has been working on Translucent Sun Visor Innovations targeted to deliver the following:
- Meet current Automotive FMVSS safety requirements.
- Reduce glare and still provide 95% feature functionality.
- Design for a feature add like HUD / other displays without redesigning of the base model.
- Potential packaging improvement for Tesla like Translucent Roof and Windshield design symmetry.
- Meet system-based cost targets based on current Visor costing.
Refer to:
- THE DESIGN OF SUN VISORS FOR the AUTOMOTIVE INDUSTRY.
- Next-Generation Automotive Sun Visor.
- What Future Sunvisors will look like.
Working on automotive smart windshield / window application to tint windows both in automotive mode and manual adjust. It must also be designed to block harmful UV rays and have minimum haze effect (< 5%).
Assume 12v power but looking to go beyond to make it wireless through combination of 1,000 mAh battery and / or supercapacitor combined with energy harvesting technology.
Another possibility might be to combine electrochromic windows and solar cells so that instead of uselessly reflecting away sunlight, darkened smart windows could soak up that energy and store it for later.
There are multiple Smart Glass Technology Innovators in the market – few listed below. Most of them use Electrochromic Technology (Dye or Film) or Nanotechnology:
- Pleotint LLC Suntuitive Dynamic Glass.
- Gauzy Switchable Glass.
- Smart Tint.
- MHDT.
- EAT Glass.
- Solar Control.
- Innovative Glass.
Current in market technology is:
- Electrochromic Technology – Dye or Film.
- Nanotechnology.
- Electro Magnetic.
As can note below have investigated current technology options but none provide the groundbreaking technology which can make it a MUST HAVE.
InvisiShade Film Application for Translucent in Vehicle Applications
Technology Solution identified Sept 2019
To integrate Adjustable Translucency and Sun Blocking characteristics in translucent Automotive Window Glass InvisiShade has a film that can be laminated to the translucent surface.
Application is simple once you get the correct size film from them with translucent conductive glue and electronic circuits.
- Align the electrical contact side of the switchable film with the top edge of the glass.
- Slowly pull away the protective liner and let the film adhere to the glass under its own weight.
- Use the roller to gently press on the film and adhere it to the glass as you continue to slowly pull away the liner.
- Remove any trapped air bubbles around the edges of the film.
- Once the film is installed solder the electrical cable to the mesh contacts.
- Check operation of the film by connecting its wires to a switch and fused power supply.
- Remove the protective liner.
- For trim recommendation is to use non-‐acid-‐based silicone along the electrical contact edge to hold trim in place. The trim should be plastic, wood, or a non-‐conductive material of your choice.
NOTES:
1. The bus bar (copper strip with the electrodes) is approximately 1/4” wide. It can be installed on any edge.
2. Edge where the electrodes are placed must be covered by 3/4” of nonconductive tape or trim under the electrodes.
3. If you must make a hole in the film, be sure to leave a minimum 1/2” of unaltered film between the hole and the edge of the film.
4. Max. 3/8” empty space between hole and PDLC matrix.
For more on InvisiShade Technology Application in Automotive contact support@invisishade.com.
Design HMi working with Innovators globally has completed application design concept for next 2020 Translucent Visor Design with Following attributes:
Translucent Visor with Touch Slider to Adjust Tint Level. The tint / translucency can be adjusted to as low as 10% to block out bright NOON time sunlight to 70% for night-time.
Translucent Sun Visor with HUD Display for Daytime or Nighttime Usage. Targeted daytime intensity of 750 Lumens. HUD can be linked wirelessly to Smart Phone or vehicle systems directly or through OBD11 connector wireless interface.
Display features and location can be changed. Current display covers the entire Visor and thus is the most expensive.
Business Case for Translucent Visor w/HUD:
- Targeted fully loaded production piece cost with HUD $250 to $350.
- Current high-end HUD average cost of $650.
- Timing for validated production intent design and prototype 6 to 9 months.
- Assume 12-month ER&D < $500K.
- Visor design with wireless data HUD Display would be unique to market.
- Will enhance in vehicle value by 10x factor – bring $3,500 added value to OE.
Below are examples of current Visor design which has not changed in the last 4 decades. It is basic with under 50% customer satisfaction based on information gathers by Design HMI LLC. Between all OE’s it really adds no real value other than that envisioned in 1954! There really no functional difference, I understand, between all Visors; even the high-end Tesla Visor also shown below.
There are technology options ideally suited for enhanced function for the Visor and enhance customer satisfaction coupled with higher social media conversation / interaction brining huge market value to OE’s.
The three technology enhanced options are:
- Translucent Visor with adjustable translucency to replace basic down visor that blocks sun glare but also obstructs road view.
- Wireless vanity mirror with lighting for system cost save and easy assembly – refer http://www.designhmi.com/2019/08/04/wireless-automotive-smart-vanity-mirror/.
- Translucent Visor w/integrated HUD Display.
For more information contact designhmi@gmail.com
In automotive applications the Sun Visor is probably the most basic component assembly which has not changed in decades (Tesla being the exception). Design HMi core competence in Visor Design is limited and one of the companies with extensive experience and core customer on global basis is Daimay Automotive ( http://en.daimay.com/).
Key Feature Adds for Translucent Sun Visor
As shown below in applications for next generation eye glass – most attributes will be needed in translucent automotive visor.
UV Coating Anti-Fog Coating Oleophobic Coating
Anti-Reflective Costing Hydrophobic Coating Anti-Scratch Coating
Polaroid Lens Technology Toughened Glass HUD Display Coating 
Just Two Automotive Sun Visor Flaws that results in customer dissatisfaction of more than 50%+.
Next Generation Automotive Sun Visor Development
Currently most automotive Sun Visors are essentially similar designed to block out the high glare of sunlight and vanity mirror.
Key components of most current Sun Visors are:
- Mirror
- Lens and PCB Assembly.
- Tube Arm, Wire Frame and Carrier Tube.
- Body
- Fabric
- Connector & Wire Harness.
- Misc. minor components.
Apart from the Tesla Visor all others have been designed in as a commodity meeting no feature or design improvement. Current Visors have two distinct short-comings:
- Minimum styling with no customer focused feature adds.
- Designed for 90th percentile as not effective for drivers with height < 5.1 feet or taller than 5.8 feet. Does not really block sun glare effectively for first case and blocks road for the other.
There are some aftermarket Translucent Visors but integration over In Car Visor is not easy.
Below is example of high-end Visor with three major functional modules (solar cells, intelligent control module, liquid crystal screen). Solar cells have two roles – perceive the light intensity as the light sensor and to convert light energy into electrical energy.
Intelligent control module uses the electrical energy to control the rotation of liquid crystal molecules, the result of liquid crystal molecules rotating is the brightness of the liquid crystal screen changes.
The stronger the outside light, the greater the power, the greater the rotation angle of the liquid crystal molecules, the darker the liquid crystal screen, on the contrary, the weaker the outside light, the more transparent the liquid crystal screen. Liquid crystal will automatically adjust brightness.
Design HMI in partnership with major automotive innovator is working to develop next generation visor with feature and greater functionality for improved in car driver and passenger experience.
Target timing to complete design for next generation Visor by Mid-2019. If you have any suggestions or WANTS for the Visor, please write to designhmi@gmail.com
Bosch’s Smart Visor Tracks the Sun While You Drive
The liquid crystal display blocks the sun in just the right spots. An AI-enhanced liquid crystal display (LCD) screen that links with a driver-monitoring camera to keep the sun out of your eyes without blocking the outward view.
The visor links a simple, honeycomb-pattern LCD screen, reinforced with polycarbonate, with a driver-facing RGB camera and an electronic control unit (ECU) running an algorithm and AI program.
The camera detects a driver’s face—eyes, nose, forehead—and the shadows the sun creates on the face. AI tracks those facial landmarks, along with 
the sun’s relative position in the vehicle environment. Analyzing faces and shadows, the system essentially works backward, figuring out where light is entering the vehicle, no matter in which direction the car is headed.
That AI employs neural networks and histogram of oriented gradients methods, with Bosch-trained models for those two AI techniques. Algorithms for shadow detection and to steer the screen are trained using domain-specific input data, e.g., real-world data from the vehicle.
A patented algorithm pinpoints the driver’s eye position, and selectively darkens or lightens portions of the screen to ensure drivers aren’t blinded. The proprietary algorithm determines the shadows and where to block corresponding sections of the visor surface. 90 percent of the visor field remains transparent at all times, no matter the sun’s intensity or angle, which eliminates that annoying limbo where drivers constantly adjust their visor or try to peer under or around it.
One cool bit is that, with driver-monitoring cameras now gaining traction in luxury cars, including the Cadillac CT6, to safely manage semi-autonomous driving functions, the Virtual Visor might become an affordable add-on: If a camera and computing power is already onboard, all that’s needed is the visor and more lines of code.
