Consumer Electronics Applications

Headlamp Battery Manufacturer in India

As a headlamp battery manufacturer in India, Leolus Energy builds compact lithium packs for professional-grade headlamps used in mining, construction, emergency response and outdoor work. These are ZERA custom packs, built to the lamp's specification rather than pulled from a catalogue, and they are made at our Bangalore facility.

A headlamp battery is a small pack with an unusually demanding duty cycle: it is run flat regularly, charged overnight on a fast turnaround, and expected to hold a steady output so that light levels do not fade through a shift. That combination — deep discharge tolerance, stable voltage under load and fast charging — is what the pack has to be designed for.

Headlamp Battery Specifications

ParameterWhat Leolus Energy builds
Voltage options3.7V (single cell), 7.4V (2S), 12.8V LiFePO4 and 14.8V (4S)
Capacity range2600mAh to 9000mAh, with custom capacities for OEM volumes
ProtectionIntegrated BMS with over-charge, over-discharge and short-circuit protection
Built forDeep discharge tolerance, stable output under load, fast charging
Form factorCustom, designed around the lamp housing and connector
SupplyFactory-direct from Bangalore, OEM labelling and GST invoicing available

Exact voltage and capacity are set by your lamp's driver and runtime requirement — share the lamp specification or the existing pack and we will confirm the right configuration.

Where These Packs Are Used

Mining headlamps

Cap lamps that must hold usable output for a full underground shift, charged on a fixed daily turnaround.

Construction & site work

Work lights and head torches exposed to dust, vibration and wide temperature swings on site.

Emergency & safety lighting

Emergency lighting and safety equipment where the pack sits at charge for long periods and must work on demand.

Portable work lights

Handheld and portable lighting needing durable packs with deep discharge tolerance.

Headlamp Batteries — FAQs

Most professional headlamps run on a single 3.7V lithium cell or a 7.4V two-cell pack; higher-output industrial lamps use larger configurations. The correct answer is whatever the lamp's driver was designed for, so the safest starting point is the voltage and capacity printed on the existing pack or in the lamp's manual. Leolus Energy builds consumer-electronics packs at 3.7V, 7.4V, 12.8V (LiFePO4) and 14.8V.

Our consumer-electronics lithium packs run from 2600mAh to 9000mAh, with custom configurations available for OEM volumes. Which capacity is right depends on the lamp's output in lumens and the runtime a shift actually requires — a mining lamp expected to hold output for a full underground shift needs a very different pack from an occasional-use outdoor headtorch.

In most cases yes. Share the existing pack's voltage, capacity, physical dimensions and connector, and we will confirm compatibility or quote a locally manufactured equivalent. This applies to imported lamps whose original packs are no longer available or have become expensive to source.

Work lights get run flat. A headlamp is used until it stops giving usable light, which means the pack is repeatedly taken to the bottom of its range — the condition that ages a poorly protected lithium cell fastest. Packs for industrial headlamps, emergency lighting, safety equipment and portable work lights are therefore built with deep discharge tolerance and a BMS that protects the cell at the low end rather than simply cutting off.

Yes. Leolus Energy manufactures ZERA custom lithium battery packs for consumer-electronics OEMs from its Bangalore facility, headlamps included, with OEM labelling and GST invoicing. Share your annual volume, the lamp specification and the target form factor to get a quote.

Need a headlamp pack built to your lamp? Request a quote, speak with our engineering team, or see all consumer electronics battery solutions and OEM battery supply.

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