Construction workers face extreme mental and physical strain due to long hours, heat stress, and heavy machinery operation. In the U.S. alone, over 874 construction deaths in a single year were linked to fatigue-related lapses in attention and cognitive performance. Despite this, there is no practical, scalable solution in the field that can monitor worker mental state and intervene in real time. Clinical EEG systems are bulky and expensive, while consumer-grade EEG devices lack the accuracy and ruggedization needed for job sites. This leaves a critical safety blind spot unaddressed.

AlphaSync is a lightweight, non-invasive EEG helmet designed specifically for industrial field workers. It uses embedded dry electrodes to monitor brainwave activity related to cognitive fatigue, stress, and distraction. By processing this data in real-time using a compact microcontroller (ESP32) and deep learning algorithms, AlphaSync can detect signs of reduced cognitive performance and immediately alert the user through haptic vibration or visual cues. The device also offers optional wireless integration with safety dashboards and digital twins for predictive safety analytics across an entire worksite.

Dry electrodes positioned at Fp1, Fp2, Cz, and Fz detect EEG signals from the scalp. These signals are sampled and filtered using onboard signal processing and a trained Convolutional Neural Network (CNN), which is optimized for noisy, high-vibration environments typical of construction sites. When cognitive drift or early signs of drowsiness are detected, the device activates an alert system (e.g., LED or vibration motor) to nudge the worker back into focus. Optional LoRa or Bluetooth communication modules allow supervisors to monitor worker status from a distance or integrate the data into a central system.

AlphaSync advances beyond existing EEG products in three ways: It’s field-ready, ruggedized, and optimized for industrial use—unlike fragile or entertainment-focused consumer EEGs. It applies edge AI to perform accurate, real-time fatigue detection on-device, without relying on cloud processing. It includes direct user alerts, enabling immediate behavioral correction without the need for interpretation or intervention from a supervisor. No currently available product offers this combination of EEG-grade accuracy, real-time response, and deployability for construction or industrial safety.

Primary applications include construction, mining, logistics, and aviation ground operations—any environment where fatigue can result in catastrophic errors. The Total Addressable Market (TAM) for wearable safety technology exceeds $1.6 trillion globally. AlphaSync targets a $1.5 billion construction safety segment, with a three-year obtainable market (SOM) of $600K through helmet sales, plus an additional $300K annually from SaaS-based safety dashboards and analytics subscriptions.

AlphaSync can be mass-produced using injection-molded ABS for the helmet, with medical-grade silicone mounts for electrodes and a modular PCB for signal acquisition and processing. This keeps production costs 60–70% lower than clinical EEG systems and 40% lower than most high-end consumer EEG headsets, making it accessible for bulk deployment by construction companies.

By preventing fatigue-related accidents, AlphaSync directly improves workplace safety, saves lives, reduces insurance costs, and increases worker productivity. It empowers organizations to automate cognitive risk detection, protect vulnerable workers, and foster safer, smarter job sites.