US Patent 12025297 Headlamp integrated into a flexible composite headband

This disclosure provides a portable lamp worn on the head and method of construction for the portable lamp. The construction method forms a composite structure that improves the comfort, reduces the volume, and better distributes the weight of the components of the lamp. The method of construction allows for a flexible material or set of flexible materials to be used to encapsulate the rigid parts of the headlamp. The flexible and rigid materials can be joined together in a heat press process that results in a single composite structure that has both attributes of the rigid material(s) and the flexible material(s) in different areas of the lamp. The battery can be located at the back or otherwise remote from the light to improve weight distribution and comfort for the user.