The Most Visible Upgrade to Rider Safety.

In the rapidly advancing market of smart and high-visibility headwear, your choice of manufacturing partner is critical. You need a partner who is not just an assembler, but a true expert in both traditional helmet safety and modern electronics integration. SPIRIT is that partner. With nearly two decades of manufacturing experience and a dedicated R&D team of mechanical and electronics engineers, we provide a seamless, end-to-end solution for your led helmet project. From initial concept and circuit design to in-house impact and electronics testing, we manage every step to ensure your final product is innovative, reliable, and fully certified. We speak the language of lumens, IP ratings, and CPSC standards. Partner with SPIRIT to develop a cutting-edge led helmet that will set your brand apart and provide a new level of active safety for your customers.

A reliable rechargeable system in an led helmet depends on three things: a high-quality battery, a modern charging interface, and a smart circuit design. At SPIRIT, we use high-quality Lithium-ion (Li-ion) or Lithium-polymer (Li-Po) batteries from reputable suppliers that are tested for safety and cycle life. For the charging interface, we strongly recommend and use the USB-C standard. It is more robust and easier for consumers to use than the older Micro USB standard. Finally, the Printed Circuit Board (PCB) is designed with protective circuits to prevent overcharging, over-discharging, and short circuits, which extends the battery's lifespan and ensures safety. A low-battery indicator is also a crucial feature that we integrate. By focusing on these three key areas, we build a reliable and user-friendly rechargeable led helmet.

The water resistance of an led helmet is indicated by its IP (Ingress Protection) rating. This two-digit code tells you how well the electronics are sealed against solids and liquids. For helmets, the second digit is the most important. A rating of IPX4, for example, means the helmet is protected against splashing water from any direction, making it suitable for riding in the rain. A rating of IPX5 or IPX6 indicates protection against more powerful water jets. It is generally not recommended to fully submerge an led helmet unless it has a very high rating (IPX7 or above). As a manufacturer, SPIRIT designs and tests our helmets to achieve a minimum of IPX4, ensuring that the lighting system remains reliable even when a rider is caught in bad weather. Always check the IP rating to understand the level of water resistance your helmet offers.

The OEM process for an led helmet is more complex than for a traditional helmet, requiring deep collaboration between the brand and a technically proficient manufacturer. The process at SPIRIT begins with a detailed technical consultation to define the desired features: brightness, battery size, charging method, and smart functions like turn signals. Our R&D team then engineers the electronic "guts" and designs how they will be integrated into the helmet's structure without compromising safety. We create a non-functional "looks-like" prototype for aesthetic approval, followed by a fully functional prototype for electronic and safety testing in our lab. Once the design is validated and approved, we move to production, which includes specialized assembly and quality control steps for the electronic components. Finally, we manage the entire certification process, ensuring the led helmet is compliant with all relevant safety and electronics standards for your target market.