The Smart Helmet: Industrial Design, Electronics, and Firmware — Built End to End

Certified head protection that simultaneously serves as the site's sensing, positioning, and communication hub. Engineered and manufactured by us from the ground up.

Every industrial workforce management system faces the same adoption hurdle: what does the worker actually carry? Badges stay in lockers, tags get forgotten, and mobile phones are banned or unsafe. A helmet is the one piece of equipment a worker cannot enter the site without. That is why we integrated sensing, precision positioning, and voice communications directly into the shell — eliminating the need to carry loose devices.

Building this requires far more than adding electronics to an off-the-shelf shell. The helmet remains certified PPE first: it must absorb impact energy and resist penetration. Weight distribution, balance, mounting rigidity, ventilation, and thermal dissipation are engineered to maintain compliance without compromise.

We own the full technology stack: mechanical design, PCB layout, embedded firmware, edge AI, RF protocols, and the backend platform. With zero reliance on third-party reference designs, we can rapidly adapt any hardware or software layer to field requirements and deploy updates over the air to active helmets on site.

Specifications of the shipping device, model N001, from its operator documentation. Battery endurance depends on the mix of video, voice and telemetry in actual use.

What Is Inside

Certified PPE First

Certified to EN 397:2012+A1:2012 for impact absorption and penetration resistance — the mandatory European standard for industrial head protection. Every internal electronic component is engineered to preserve full structural safety.

Integrated Multi-Mode Positioning

Embedded UWB and satellite RTK receivers provide continuous high-precision tracking with automatic indoor/outdoor handover. Zero standalone tags to issue, charge, track, or lose.

Autonomous Edge Sensing

Integrated IMU sensors (accelerometer, gyroscope, magnetometer), a barometer, and proximity sensing detect falls, impacts, and helmet-wearing status in real time. Each kit includes a companion wristband for vital sign monitoring, with optional multi-gas sensing (O₂, H₂S, CO, combustible gases) paired seamlessly.

One Cohesive Kit Instead of Standalone Devices

The helmet integrates the capabilities of a two-way radio, positioning tag, inspection camera, and safety sensors, operating in seamless sync with the included wristband and optional gas detector. It eliminates the need to manage, charge, and inventory multiple disconnected handheld gadgets from different vendors.

Voice Engineered for Extreme Noise

Integrated Push-to-Talk eliminates handheld radios and phones. Communication channels follow the worker automatically by zone or operational role, with voice commands supported in the worker's native language.

First-Person Remote Assistance & QA

Connect off-site specialists directly to the worker's perspective to guide complex tasks, troubleshoot issues, and verify installations in real time. High-efficiency video streaming enables remote acceptance inspections, automatically attaching visual records to project logs.

Specifications

What ships today and what does not

EN 397 certification is held. Certification for the United States and Canada has been initiated and is not complete — we say so plainly rather than implying global coverage.

Positioning has prerequisites and we would rather state them than let them surface during a pilot: satellite RTK needs a correction base station, and UWB positioning needs beacons deployed at the site. GNSS alone works outdoors without either.

Vital-sign monitoring comes from the fitness band that ships with the helmet, not from sensors in the shell.

Voice-based screening for alcohol impairment is a production capability with published results. Fatigue detection is in development and is not a shipped feature; we do not present the two as one.

Presence, time in zones and productivity accounting already run in real time — that is what the positioning layer delivers today. What is still ahead is classification of work by activity type and the AI Copilot built on top of it: the sensors' neural processors are currently assembling the dataset that step requires.

Battery figures come from the stated usage mixes. A shift dominated by continuous video will not match a shift of telemetry and occasional voice, and no single number honestly covers both.

What the helmet makes possible

Objective presence and time in work, hazard, service and waiting zones

Hazard-zone entry detected at the moment it happens, not after the shift

Automatic PPE control and a continuous digital HSE audit

Fall and impact detection routed straight to the control room

Remote expert assistance through the worker's own point of view

Crew coordination and live translation without phones or separate radios