Technology That Lights the Way.

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 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.

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.

While the led helmet is most common in cycling and commuting, the technology is increasingly being integrated into other sports. For a ski helmet, a rear-facing red LED light can dramatically increase a skier's or snowboarder's visibility to others on the mountain, especially in flat light, foggy, or snowy conditions, helping to prevent collisions. For skateboarding, especially for those who skate at dusk or use their board for commuting, front and rear lights serve the same critical safety function as they do for cyclists. The manufacturing challenge, which SPIRIT is equipped to handle, is to ensure the electronic components are robust enough to withstand the colder temperatures of skiing and the higher-vibration environment of skateboarding, all while meeting the specific impact standards for those sports (like ASTM F2040 for snow sports).