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Fogging (i.e. condensation of water vapor) in headlamps in severe weather conditions present both a performance and potential safety concern for automotive companies. Conventional headlamps are based on incandescent bulbs. In recent times, LED lighting has increasingly become the norm. However, LED based headlamps are prone to higher levels of fogging because they inherently produce less heat than the conventional incandescent or halogen bulbs. A headlamp design must be able to dispose all the formed condensate/fog in a fixed time even under severe thermal conditions. It is of great importance for the car manufacturer to be able to simulate the risk of condensation early in the design stage with an eye on the overall cost reduction. The combined use of experimental studies and numerical modelling is important to optimize headlamp design and to produce high-performance headlamps.