Custom Machines Case Studies

Custom Machine Fabrication of Prototype Interior light Bar for New Era of Police Vehicle

Custom Machine DesignThrough custom machine fabrication, EPIC helped an emergency light bar manufacturer avoid losing profits by expediting a product line redesign. New models of police vehicles were announced by precincts across the county. The light bars used in the old model vehicles would not fit inside the new cars. With vehicle orders already placed, a leading producer of emergency light bars had to act fast to not miss potential profits created by the new cars. EPIC Custom Machines designed, engineered and manufactured a light bar to meet the expedited demand of the client.

Have you ever been driving along, minding your own business, when the “normal” car behind you suddenly explodes with a symphony of flashing light and sirens? The reason you didn’t see the police vehicle is because they have an interior light bar that allows them to stay undetected. A major supplier of emergency lighting approached EPIC to engineer and manufacture custom light bars that would fit with engineered precision in the new squad cars being introduced into police departments.

Client: Leading Public Safety Equipment Company

Industry: Emergency/Warning Vehicle Lighting

Core Challenges:

  • Visibility – If you have ever been driving at night and someone in the car turns on the dome light, you know how difficult it can be to see.  If the interior light bar in the police vehicle did not seal tight to the windshield, light would leak into the squad car reducing visibility.
  • Precise fit of the light bar to vehicle interior
  • Client wanted the light bar to look as though it were another available option from the dealership. Leather seats – power locks – interior light bar
  • Time crunch and adaptable design: As the quintessential Crown Victoria squad cars were reaching the end of their life cycle, a new generation of squad car was being ushered in. Departments were receiving new vehicle models which expedited the time line to produce custom light bars for each new make and model.

EPIC’s Proven Solution

Machine Design and FabricationThe client’s strict time line was the driving force for working with EPIC. EPIC could deliver the fastest time to market solution because design, engineering and manufacturing of the light bar was all completed at EPIC’s facility under one project manager. They felt that one company – handling the entire project – would increase the likelihood that the project would be completed on time. EPIC’s turnkey approach and project management experience was a perfect match. EPIC’s engineers began the project with preliminary design and modeling. Achieving a precise fit with the rounded edge of the light bar to the windshield was critical to the success of the project. The more precise the fit, the less light would leak into the cab of the vehicle. Eliminating light leakage was important to the client because any light in the cab of the vehicle led to increased contrast and reduced visibility.  EPIC rented the specific vehicles models to ensure accurate measurements.

Machine Fabrication and InstallationHaving access to the make and model of the vehicle throughout the build allowed EPIC to strike the perfect match between functionality and aesthetics. The goal was to make the light bar look like any other commercial option you could add when selecting the vehicle for purchase. EPIC’s true value in this project was that engineers could walk to the shop and correspond directly with the craftsman.  The client had one point of contact throughout the entirety of the custom machine fabrication which streamlined project completion. EPIC Custom machines took this project from concept to completion, on an expedited project timeline exceeding all expectations of the client.


  1. Client could meet market demand for the new model police vehicles
  2. EPIC’s light bar eliminated light leakage keeping our first responders safe while in pursuit
  3. Completed light bar in time for client to be first to the market for the new generations of police vehicles


WHY EPIC CUSTOM MACHINES? A custom machine design firm helps you design, fabricate and integrate an appropriate custom solution that meets your unique need. EPIC believes we can help you “Do It Better” by:

  • Utilizing Front-End Engineering to ensure that the proper steps are taken during project scope development
  • Appointing a single point of direct contact during the entirety of the project
  • Maintaining an open door client policy to promote innovation. We invite clients to visit EPIC to experiment with new processes, technologies and techniques that push the limits of traditional engineering.
  • Imparting a transfer of knowledge (not just a basic training) for the machines and equipment we provide

Find a better solution. Contact EPIC or learn more about custom machine design.

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