Custom Lithium LiPo Battery Solutions for Smart Helmets

In smart helmet development, the battery is more than a power source. It directly affects product form, wearing comfort, functional scalability, and overall safety.For applications such as industrial safety helmets, cycling helmets, and AR/VR-integrated headgear, we provide a customized lithium battery solution that balances high performance, structural flexibility, and strict safety requirements—designed specifically for head-worn devices.

1. Energy Density: Balancing Lightweight Design and Long Runtime

Design challenge:
Smart helmets must remain lightweight to reduce neck strain, while supporting power-hungry modules such as cameras, wireless communication, sensors, and processors.

Our solution:
We use high-voltage 4.4V / 4.45V silicon-carbon anode lithium-ion cells, achieving a volumetric energy density of ≥750 Wh/L.

• 20–30% longer runtime at the same weight
• Fewer cells or smaller battery volume required
• Supports all-day operation for continuous recording and connectivity

Result:
Longer endurance without compromising wearing comfort or industrial design.

2. Space Optimization: Battery Shapes Designed for Helmet Structures

Design challenge:
Helmet interiors are curved, compact, and irregular. Standard prismatic or cylindrical batteries waste valuable space and limit structural freedom.

Our solution:
We offer custom-shaped battery cells engineered to match helmet geometry.

• Curved, circular, stepped, and irregular cell designs
• Ultra-thin construction, as thin as 0.5 mm
• Seamless integration into helmet liners or internal layers

Result:
Maximum space utilization without affecting aerodynamics or exterior aesthetics.

3. Thermal Performance: Stable Operation in Extreme Environments

Design challenge:
Smart helmets operate outdoors, facing cold weather, high summer temperatures, and heat buildup during high-speed movement or continuous use.

Our solution:

• Wide-temperature cell technology
• Operational range from −20°C to 60°C
• Low internal resistance to minimize self-heating
• Multi-point NTC temperature monitoring for real-time protection

Result:
Consistent performance and predictable safety behavior across all climate conditions.

4. Fast Charging: Designed for Fragmented Usage Scenarios

Design challenge:
Long charging times reduce usability, especially when helmets are used intermittently throughout the day.

Our solution:

• Supports up to 3C fast charging
• More than 50% charge in 15 minutes
• Magnetic charging interface optimized for helmet products
• Charge-pump architecture improves efficiency while reducing charging heat

Result:
Short charging sessions provide meaningful runtime without compromising battery life or safety.

5. Safety: A Non-Negotiable Requirement for Head-Worn Devices

Design challenge:
Helmets must remain safe under impact, vibration, drops, and even penetration. Battery failure is not acceptable in head-mounted equipment.

Our solution:

• Solid-state or semi-solid electrolyte options
• No fire or explosion under impact or puncture conditions
• V-0 flame-retardant packaging materials
• Reinforced composite aluminum-plastic film
• Dual-layer hardware protection for overcharge, over-discharge, and short circuit
• Compliance with GB 31241, UL 2054, CE, and other global standards

Result:
A battery system designed to protect both the product and the user under extreme conditions.

Key Technical Specifications

A Battery Solution Designed for Smart Helmets — Not a Compromise

A well-designed smart helmet is not built by stacking features, but by achieving system-level balance between performance, safety, structure, and user experience within extremely limited space.

MOTOMA’s customized lithium battery solutions are developed specifically to meet all smart helmet requirements, addressing the most common challenges in the market:

• Lightweight design with extended runtime
• Complex structural compatibility
• Fast, low-heat charging
• Stable performance across extreme temperatures
• High safety margins for head-worn applications
• Reduced integration risk and long-term ownership cost

Rather than forcing a standard battery into a specialized product, MOTOMA builds the battery around the helmet itself.

From concept development and prototyping to validation and mass production, MOTOMA serves as a long-term power solution partner for smart helmet projects worldwide.