Systems and methods for assembling a head-mounted display
Methods of assembling a head-mounted display (HMD) may include coupling a first digital projector assembly to an HMD frame, coupling a second digital projector assembly to the HMD frame, and then warping the HMD frame to optically align the first digital projector assembly with the second digital projector assembly. The warped HMD frame may be fixed such that the first digital projector assembly and the second digital projector assembly are optically aligned to within a predetermined threshold. Various other methods and systems are also disclosed.
1. A method of assembling a head-mounted display (HMD),
the method comprising:
coupling a first digital projector assembly to an HMD frame;
coupling a second digital projector assembly to the HMD frame;
after the first digital projector assembly and the second digital projector assembly are coupled to the HMD frame, warping the HMD frame to optically align the first digital projector assembly with the second digital projector assembly; and
fixing the warped HMD frame such that the first digital projector assembly is optically aligned to the second digital projector assembly to within a predetermined threshold,
wherein fixing the warped HMD frame comprises permanently securing an enclosure to the HMD frame while holding the HMD frame in a warped configuration.
2. The method of claim 1 , wherein warping the HMD frame comprises at least one of:
bending the HMD frame; or
twisting the HMD frame.
3. The method of claim 1 , further comprising, prior to warping the HMD frame, determining an offset between a first optical output of the first digital projector assembly and a second optical output of the second digital projector assembly.
4. The method of claim 3 , wherein determining the offset comprises:
measuring a first angle of the first optical output relative to an optical coordinate system associated with at least one optical alignment camera;
measuring a second angle of the second optical output relative to the optical coordinate system; and
determining an angular difference between the first angle and the second angle.
5. The method of claim 1 , wherein warping the HMD frame comprises:
overwarping the HMD frame past a target geometry of the HMD frame; and
allowing the overwarped HMD frame to spring back to the target geometry, wherein the first digital projector assembly and the second digital projector assembly are optically aligned to within the predetermined threshold when the HMD frame has the target geometry.
6. The method of claim 1 , wherein permanently securing the enclosure to the HMD frame comprises at least one of:
fastening the enclosure to the HMD frame;
adhering the enclosure to the HMD frame; or
welding the enclosure to the HMD frame.
7. The method of claim 1 , further comprising heating at least a portion of the HMD frame to facilitate the warping of the HMD frame.
8. The method of claim 1 , wherein at least portions of the HMD frame that are warped comprise at least one of:
a metal material; or
a polymer material.
9. The method of claim 1 , wherein coupling the first digital projector assembly and the second digital projector assembly to the HMD frame comprises fastening the first digital projector assembly and the second digital projector assembly to the HMD frame with at least one screw or bolt.
10. The method of claim 1 , wherein:
coupling the first digital projector assembly to the HMD frame comprises abutting the first digital projector assembly against a first surface of the HMD frame; and
coupling the second digital projector assembly to the HMD frame comprises abutting the second digital projector assembly against a second surface of the HMD frame.
11. The method of claim 1 , wherein the HMD frame comprises an augmented-reality glasses frame.
12. The method of claim 1 , further comprising coupling at least one waveguide to the HMD frame to direct a stereoscopic image generated by the first digital projector assembly and the second digital projector assembly to a location in front of an intended user's eyes.
13. A method of assembling a head-mounted display (HMD),
the method comprising:
coupling a first digital projector assembly and a second digital projector assembly to an HMD frame including abutting the first digital projector assembly and the second digital projector assembly against the HMD frame;
after the first digital projector assembly and the second digital projector assembly are coupled to the HMD frame, warping the HMD frame to align a first optical output of the first digital projector assembly with a second optical output of the second digital projector assembly; and
after warping the HMD frame, permanently securing an enclosure to the warped HMD frame to fix the warped HMD frame in a target geometry such that the first digital projector assembly is optically aligned to the second digital projector assembly to within a predetermined threshold.
14. The method of claim 13 , wherein the predetermined threshold is 10 arcminutes or less.
15. The method of claim 13 , wherein warping the HMD frame comprises overwarping the HMD frame past the target geometry and allowing the overwarped HMD to spring back to the target geometry.
16. The method of claim 13 , wherein warping the HMD frame comprises at least one of:
bending the HMD frame; or
twisting the HMD frame.
17. The method of claim 13 , wherein permanently securing the enclosure to the HMD frame comprises at least one of:
fastening the enclosure to the HMD frame;
adhering the enclosure to the HMD frame; or
welding the enclosure to the HMD frame.