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The mould library, with the numbers attached.

Every model on this page is a mould we own and keep in production. The confirmed figures — output, mass, ingress, housing and light sources — are below; beam distance and runtime will be released with the ANSI/NEMA FL1 report at launch. Choose a platform; the performance tier is yours to set.

Code Model Housing Status Sample lead time
HL-M1 Ultralight flagship Die-cast magnesium​ Launching Q4 2026 From Q4 2026
HL-M2 Compact everyday Die-cast aluminium and CNC machining​ Tooling · 2026 Q4 Samples 2027 Q2
HL-M3 High-output professional Die-cast aluminium In production Samples from Nov 2026

Sample lead time is the time to a branded, measured pre-production unit on an existing mould. It assumes the specification is already fixed — the option matrix on the ODM page shows what can change.

HL-M1 · Ultralight flagship

The lightest metal body we make.

Launching Q4 2026 Headlamp · cell in body
M1 headlamp in six views: three-quarter, both front quarter views, side, front and rear
Six viewsOne cast body, one sealed window, two optical paths behind it. Colourway shown is a render study — production finishes are set per programme.

Same three duties as every headlamp — structure, heat path, sealing — carried in a metal at roughly two-thirds the density of aluminium. The M1 is not an M3 with a different alloy order: magnesium fills thin sections at a different rate, needs its own cover gas, and the raw casting needs a conversion coating before paint will hold. All three of those are solved in the design and the supply chain we manage. What the wearer gets is the same thermal work at the front of the head with less mass on the band; what you get is a metal-bodied headlamp that still lands in a mid-market retail band instead of a specialist one.

1,600–1,800lm
Max output
170m
Beam distance, target
≤135g
With battery & band
IP68
Sealing, 2 m submersion

Output & runtime

  • Max output1,600–1,800 lm
  • Beam distance170 m (ANSI FL1, target)
  • Light sourcesSpot + wide flood + red
  • RuntimeFull mode table on the FL1 datasheet at launch

Optical & power

  • LEDHigh-power spot + flood, bin-selected
  • Colour temperature5,000 K neutral + 3,000 K warm + red
  • CRI90+ on flood
  • OpticTIR spot over reflector flood
  • Battery1× 18650 Li-ion (CR123A backup)
  • ChargingUSB-C

Body & finish

  • HousingMagnesium die-cast, AZ91D
  • BezelCNC-machined, anodised
  • ControlDual top buttons + electronic lockout
  • BandOne-hand adjustable, silicone grip + whistle
  • BrandingLaser-marked, nothing moulded in

Environment

  • IngressIP68 — 2 m submersion
  • Impact2 m drop, six faces
  • Operating temp.−20 °C to +55 °C
  • Mass, with cell & band≤135 g
  • Charging portUSB-C under sealed flap
Close-up of the M1 head: two lens apertures in one sealed metal window, with the knurled cell cap above
WindowTwo lenses, one sealed window: spot above, flood below, compressed on a single machined land.
Close-up of the M1 band buckle, adjuster and perforated silicone grip
BandAdjuster, buckle and silicone grip — the parts of a programme that change without touching the head mould.
M1 headlamp in left front three-quarter view on its band loop
Three-quarterHead, bracket, band. The cast body carries the heat path and the sealing land; the bracket and band are the stocked parts around it.
M1 headlamp rear view showing the band bracket and its adjustment dial
RearThe rear bracket carries the adjuster, so the cast body does not have to double as a hinge.
  • Fixed on this mould: housing geometry, optic position, sealing groove, button location, band anchors.
  • Yours to set: LED bin and colour temperature, driver output levels, battery capacity, finish and colourway, logo, packaging, accessories, plug and market label.

Output, mass, ingress, housing and light-source figures are confirmed for the current configuration. Beam distance and runtime are design targets pending the ANSI/NEMA FL1 third-party report, issued with the datasheet at launch. All figures are measured on the in-house integrating sphere at 25 °C ambient; a datasheet is issued against the exact configuration you order.

HL-M2 · Compact everyday

The compact headlamp, built for every day.

Tooling · 2026 Q4 Headlamp · cell in body

The M2 keeps the die-cast metal philosophy of the M3 — a machined, sealed metal body rather than a moulded shell — but folds the cell into the lamp itself, which is what lets it sit in the everyday and retail-volume tier. Less output, less mass, the same sealed metal construction.

Like every library model, nothing is moulded in: the window frame, the end caps and the band anchors are all faces we can cut and mark for your programme.

HL-M2 aluminium die-cast headlamp on its headband, three-quarter view
1,200lm
Max output
175m
Beam distance, ANSI FL1
105g
With battery & band
IP68
Sealing, 2 m submersion

Output & runtime

  • Max output1,200 lm
  • Beam distance175 m (ANSI FL1)
  • Light sourcesSpot + flood + guide-light red
  • RuntimeFull mode table on the FL1 datasheet at launch

Optical & power

  • LEDTriple-source: spot + flood + red
  • Colour temperature5,000 K neutral, CRI 90+ (flood)
  • Red lightSteady + flash (also lockout entry)
  • OpticMulti-element reflector
  • Battery1× 18350 Li-ion (in-lamp)
  • ChargingUSB-C — body and pocket cell

Body & finish

  • HousingAluminium die-cast, A6061-T6
  • ControlSingle side button + lockout + low-batt warning
  • BrandingLaser-marked, nothing moulded in

Environment

  • IngressIP68 — 2 m submersion
  • Impact2 m drop, six faces
  • Operating temp.−20 °C to +55 °C
  • Mass, with cell & band105 g
  • Charging portUSB-C under sealed flap
HL-M2 headlamp front elevation: two apertures behind one sealed window, band at full width
FrontTwo sources behind one sealed window — a reflector for throw, a TIR lens for flood.
HL-M2 headlamp in side profile, short body mounted on the headband
SideShort body, no rear pack: the cell rides inside the tube, so the band carries only the light.
HL-M2 headlamp three-quarter view on its band, showing both knurled end caps
Three-quarterOne cast body, two knurled caps, one switch. Everything else is sealing and structure.
HL-M2 headlamp seen from the rear: the band with only the mount bracket at the centre
RearA bracket is all that sits behind the head — no cell pack riding at the back of the band.
Close-up of the HL-M2 machined window frame, twin optics and knurled end cap
WindowFrame, optic and cap are machined after casting — these are the fits that decide whether it seals.
Close-up of the HL-M2 woven elastic band, moulded adjuster and side buckle
BandWoven elastic, moulded adjuster, a buckle at each side — the band carries the light, so it gets real hardware.

Output, beam distance, mass, ingress, housing and light-source figures are measured on the current configuration to ANSI/NEMA FL1. Per-mode runtime is published with the full datasheet at launch.

HL-M3 · High-output professional

The platform the factory was built around.

In production Headlamp · rear pack

A high-output head carries mass: heat path, cell, driver. Keep all of it on the forehead and the wearer pays for it after forty minutes. The M3 moves the cell to a rear pack and leaves the front housing to the metal that has to be there anyway.

The bezel is machined, not cast, so the lens sits on a flat face with measurable gasket compression. Six screws mean the lens is serviceable in the field rather than a sealed unit you throw away.

HL-M3 headlamp, three-quarter view: orange machined bezel, six screws and rear battery pack
HL-M3 · shown in a custom orange bezel
4,000lm
Max output
450m
Beam distance, target
413g
Measured, with pack
IP68
Sealing, 2 m submersion

Output & runtime

  • Max output4,000 lm
  • Beam distance450 m (ANSI FL1, target)
  • Light sources1× spotlight + 2× flood + front red
  • RuntimeFull mode table on the FL1 datasheet at launch

Optical & power

  • Front red lightIndependent LED — high / low / flashing
  • Colour temperatureNeutral white + warm white
  • ThermalSmart step-down management
  • BatterySplit pack, 2× 21700 Li-ion
  • ChargingUSB-C, rechargeable

Body & finish

  • HousingAluminium die-cast
  • SwitchingRotary selector + electronic button, lockout
  • MountingHelmet / NVG compatible
  • Standard colourBlack (custom from 1,000 pcs)
  • BrandingLaser-marked, nothing moulded in

Environment

  • IngressIP68 — 2 m submersion
  • Impact2 m drop, six faces
  • Operating temp.−20 °C to +55 °C
  • Mass, with pack413 g (measured)
  • Charging portUSB-C
HL-M3 headlamp front view: orange bezel, single lens over the multi-element optic
FrontOne lens over a multi-element optic — spot and wide flood mixed behind the same glass.
HL-M3 headlamp in side profile showing the head at the front and the battery pack at the rear
SideHead forward, cell behind — the band carries the pack so the forehead carries only the light.
HL-M3 rear pack on the band with strain-relieved cable entry and buckles
RearSplit pack on the band: two 21700 cells, strain-relieved cable entry, adjusters each side.
HL-M3 from above at 45 degrees showing the crown strap and rotary selector
TopThe wheel is the only control on the body; everything else is sealing and structure.
Close-up of the HL-M3 machined bezel, six screws and multi-element optic
BezelMachined, screwed down, gasket compression you can measure instead of hope for.
Close-up of the HL-M3 woven elastic band and moulded adjuster buckles
BandWoven elastic, moulded adjusters — tension that holds after a shift, not just on the bench.

Shown in a custom orange bezel; standard production is black, with any colour from 1,000 pcs. Output, mass, ingress, housing and light-source figures are confirmed for the current configuration. Beam distance and runtime are design targets pending the ANSI/NEMA FL1 third-party report, issued with the datasheet at launch.

Why die-cast metal

Plastic housings are cheap until the LED gets hot.

High output in a head-mounted light means heat has nowhere to hide. A die-cast body — aluminium where cost matters, magnesium where every gram counts — spreads and dissipates it, keeps the driver and cell inside their limits, and holds its shape through drops and pressure changes.

  • Better thermal path, so a higher output class stays usable instead of stepping down in seconds
  • Structural stiffness without extra wall thickness, which keeps weight off the forehead
  • Stable sealing geometry under heat cycling and impact
  • Premium feel in hand — the difference a buyer notices before reading the spec sheet
Aluminium die-casting machine casting headlamp housings at a partner foundry
PartnerCast to our tooling, machined to our drawings

Ask for the datasheet, not the brochure.

Any model on this page comes as a PDF datasheet with the test data behind it — and a sample you can measure yourself.

Request a datasheet What can I change?