First off, who said anything about federal requirements for headlamps?
Nobody. You claimed there are DOT regulations for aftermarket (i.e., auxiliary) lights, and the fact is there aren't.
Different states have different rules concerning lighting on vehicles that can supersede any federal mandate.
You've got that backwards. Federal regulations supersede state regulations; states aren't permitted to have regulations that differ from the federal reg for any given item or system of vehicle equipment. If (and only if) there is no federal regulation on an item or system (such as auxiliary lamps) then states may regulate the installation and usage of the device or system to the degree (and only to the degree) any such regulation does not bar the sale or use of a vehicle fully compliant with all applicable Federal standards.
California does not allow non-DOT lights to be mounted in a forward direction
You're misreading and/or misunderstanding the California vehicle code. There's no such thing as a "DOT fog lamp", for example, because there are no federal fog lamp regulations. Nevertheless, many vehicles come with fog lamps -- none of which are marked "DOT", and all of which are permitted in California, because California's not permitted to ban vehicles compliant with all applicable federal vehicle safety standards.
Again, it is not cheap to make a light that complies with DOT requirements. It is even harder to make a light that is "universal" and can do this.
Nope. It's very easy to make a fog lamp or an auxiliary high beam ("driving") lamp that conforms to the relevant SAE and/or ECE technical standards, and then the only variability among states is how many are permitted per vehicle, how high and low they can be mounted, how they can be hooked up with respect to other lights on the vehicle, and when they may and may not be used. You are still pleading regulatory difficulty that does not really exist. Is it because you don't understand the regulations, because you don't want to share the real reason, or both?
please educate me on how you can use the reflective and refractive properties of any thermoplastic to create an optic that can be effectively injection molded and mass produced.
Uh...sure, as soon as you pay me engineering-school tuition, I'll be glad to teach you a private class. Or you could save big bucks and do some research on your own. There's a great deal of material published on that very topic and many related ones. It's not very hard to find, either, though some of it isn't free.
how much do you think it costs to engineer and tool for 1 optic?
Between several hundred thousand and a million dollars, in rough numbers, depending on the complexity of the optic. Having developed several commercialized headlamps, I don't need to guess or surmise.
I didn't know that Caddy had that light
...but you had no qualm about asserting that they don't.
I am glad they are using LEDs, but their light is designed for 1 vehicle. It has multiple projectors to achieve the necessary pattern needed for safe driving.
Yeah...and what's your point here? It's an all-LED headlamp. You claimed nobody is using LEDs for headlamps. You're wrong several times over.
Give Hella a call and ask them if they recommend using the Escalade light on your beat up Honda and let me know what they say.
Here's a more relevant question: How many different makes and models d'you suppose
Truck-Lite's all-LED 7" round high/low beam street-legal headlamp fits? (hey, look...it's another one of those "nonexistent" LED headlamps you were talking about!)
If you are going to make accusations about the abilities of known sciences, I recommend that you pick up a book on properties of light and do a little research.
...says the guy caught out in an attempt to spread complete misinformation. Yeah, I'll get
right on that. Vision X used up most of my credulity very early on with extravagant claims backed up by nothing but handwaving, and your posts in this thread seem to be more of the same.