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    This study introduces a rapid near-eye display manufacturing pipeline, reducing lead times to one day. This innovation enables faster design iterations and exploration of novel augmented reality (AR) hardware.

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    Area of Science:

    • Optics and Photonics
    • Computer Science
    • Materials Science

    Background:

    • Traditional optical manufacturing for near-eye displays involves lengthy lead times (weeks), hindering rapid design iteration and exploration of advanced optical concepts.
    • The limitations of conventional methods restrict the development of next-generation augmented reality (AR) and virtual reality (VR) near-eye display systems.

    Purpose of the Study:

    • To develop a novel, rapid manufacturing pipeline for near-eye displays with a lead time of one day using commodity hardware.
    • To enable optical designers to iterate quickly and explore beyond conventional near-eye display designs.
    • To demonstrate the feasibility of creating high-performance, freeform optical components for AR applications.

    Main Methods:

    • Developed a rapid production technique to achieve optical quality surfaces on 3D printed components.
    • Employed a computational design methodology integrating machine learning and ray tracing for freeform projection screen surfaces.
    • Designed a custom projection lens with non-uniform pixel distribution for foveated display hardware.

    Main Results:

    • Successfully demonstrated untethered augmented reality (AR) near-eye display prototypes.
    • Achieved a ski-goggles form factor with a large monocular field of view (30°×55°).
    • Attained a high resolution of 12 cycles per degree, suitable for immersive AR experiences.

    Conclusions:

    • The presented rapid manufacturing pipeline significantly reduces lead times for near-eye displays.
    • The integration of advanced computational design and novel fabrication techniques enables high-performance AR hardware.
    • This approach facilitates the development of compact, lightweight, and high-resolution near-eye displays for future AR applications.