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A new generation of optical simulation software has been developed and is now in use to optimise the design and performance of vehicle headlamps that are destined to set new standards of lighting performance. The new system differs from previously available products in that it has greater prescriptive powers in generating the new reflector form to satisfy the input requirements. Furthermore, the structure of the software and its use make it possible to streamline the headlamp design and development process, resulting in time and cost savings. This paper discusses the principles, structure and performance features of the new software, and goes on to examine the changes possible in methodology used to organise the headlamp development and optimisation process. Finally a case study is given to illustrate the system performance.