Head-mounted-display system including three-dimensional knitted layer

1. A head-mounted-display assembly comprising:

a knitted layer formed of a plurality of fibers and extending in three dimensions to define a housing cavity, the knitted layer comprising:

a first region having a first degree of at least one physical property corresponding to a first proportion of a first type of fiber included within the first region;

a second region having a second degree of the at least one physical property corresponding to a second proportion of the first type of fiber included within the second region; and

a transition region extending between the first region and the second region, wherein the transition region of the knitted layer progressively changes in degree of the at least one physical property proceeding from the first region toward the second region; and

at least one electronic head-mounted-display component secured within the housing cavity,

wherein:

the knitted layer comprises a seamless piece extending through each of the first region, the transition region, and the second region; and

the first region has a first average layer thickness and the second region has a second average layer thickness that differs from the first average layer thickness.

2. The head-mounted-display assembly of claim 1 , wherein the at least one physical property comprises at least one of rigidity, elasticity, flexibility, deformability, or bondability to at least one specified material.

3. The head-mounted-display assembly of claim 1 , wherein the plurality of fibers comprises a plurality of yarns, each of the plurality of yarns comprising multiple fibers.

4. The head-mounted-display assembly of claim 1 , wherein the knitted layer comprises at least a portion of a display housing for mounting the at least one electronic head-mounted-display component.

5. The head-mounted-display assembly of claim 4 , wherein:

the knitted layer comprises at least a portion of at least one of a front-facing portion or a side portion of the display housing; and

the side portion of the display housing extends from the front-facing portion toward a viewing opening dimensioned to surround at least a portion of a user's face.

6. The head-mounted-display assembly of claim 4 , wherein:

the first region of the knitted layer comprises a mounting region for mounting the at least one electronic head-mounted-display component; and

the first region of the knitted layer has a higher degree of rigidity than the second region of the knitted layer.

7. The head-mounted-display assembly of claim 1 , wherein the knitted layer comprises at least a portion of a strap subsystem dimensioned to extend around at least a portion of a user's head.

8. The head-mounted-display assembly of claim 1 , wherein:

the plurality of fibers comprises the first type of fiber and a second type of fiber that comprises a different material than the first type of fiber; and

at least one of the first type of fiber and the second type of fiber comprises at least one of a thermoplastic material, a thermosetting material, or a curable material.

9. The head-mounted-display assembly of claim 8 , wherein:

the first region of the knitted layer comprises a first proportion of the first type of fiber to the second type of fiber; and

the second region of the knitted layer comprises a second proportion of the first type of fiber to the second type of fiber, wherein the second proportion differs from the first proportion.

10. The head-mounted-display assembly of claim 1 , wherein at least a portion of an electrical circuit is disposed in the knitted layer.

11. The head-mounted-display assembly of claim 1 , wherein the at least one electronic head-mounted-display component is mounted to the first region of the knitted layer.

12. The head-mounted-display system of claim 1 , wherein:

the at least one electronic component is mounted to the first region of the knitted layer by at least one of bonding or mechanical fastening; and

the first region of the knitted layer has a higher degree of rigidity than the second region of the knitted layer.

13. The head-mounted-display assembly of claim 1 , wherein:

the at least one physical property includes rigidity and the first region of the knitted layer has a higher degree of rigidity than the second region of the knitted layer; and

the at least one electronic head-mounted-display component includes at least one display screen and at least one lens for viewing the at least one display screen secured within the housing cavity via mounting to the first region.

14. The head-mounted-display assembly of claim 13 , wherein the second region of the knitted layer surrounds a viewing opening dimensioned to extend around a portion of a viewer's face to provide a view by the user of the at least one display screen via the at least one lens.

15. A method comprising:

knitting together a plurality of fibers to form a knitted layer of a head-mounted-display assembly, the knitted layer extending in three dimensions to define a housing cavity;

processing the knitted layer to produce:

a first region of the knitted layer having a first degree of at least one physical property corresponding to a first proportion of a first type of fiber included within the first region; and

a second region of the knitted layer having a second degree of the at least one physical property corresponding to a second proportion of the first type of fiber included within the second region, wherein the first region has a first average layer thickness and the second region has a second average layer thickness that differs from the first average layer thickness; and

a transition region of the knitted layer extending from the first region to the second region, wherein the transition region progressively changes in degree of the at least one physical property proceeding from the first region toward the second region, wherein the knitted layer comprises a seamless piece extending through each of the first region, the transition region, and the second region; and

securing at least one electronic head-mounted-display component within the housing cavity.

16. The method of claim 15 , wherein, during the processing, at least a portion of the knitted layer is exposed to at least one of elevated heat, elevated pressure, light, radiation, or at least one chemical agent sufficient to modify the at least one physical property of at least the portion of the knitted layer.

17. The method of claim 15 , wherein, during the processing, at least a portion of the knitted layer is at least one of softened, melted, cured, or molded.

18. The method of claim 15 , the first region of the processed knitted layer is configured to have the at least one head-mounted-display component mounted thereto, wherein the at least one head-mounted-display component is mounted to the first region of the processed knitted layer by at least one of bonding or mechanically fastening the at least one head-mounted-display component to the first region of the processed knitted layer.

19. The method of claim 15 , wherein:

the first region of the knitted layer comprises a first proportion of the first type of fiber to a second type of fiber; and

the second region of the knitted layer comprises a second proportion of the first type of fiber to the second type of fiber, wherein the second proportion differs from the first proportion.