Design, stray light analysis, and fabrication of a compact head-mounted display using freeform prisms

It has been a challenge to design an optical see-through head-mounted display that is compact, lightweight, and stray-light-suppressed by using freeform optics. A new type of design based on freeform prisms is presented. The system consists of three optical elements and a micro-display. Two prisms serve as near-eye viewing optics that magnify the image displayed by the micro-display, and the other freeform lens is an auxiliary element attached to the main wedge-shaped prism to provide an undistorted see-through view of a real-world scene. The overall thickness of the optical system does not exceed 9.5 mm, and the weight is less than 9.8 g per eye. The final system is based on a 0.49-inch micro-display and features a diagonal field of view of 38°, an F/number of 1.8, with a 10 mm × 7 mm exit pupil diameter, and a 19 mm eye relief. The causes of stray light in the optical-mechanical system are investigated, and effective solutions or theoretical suppression of stray light are given. The freeform optical elements are successfully fabricated, and the system performance is carefully investigated. The results show that the performance of the optical see-through head-mounted display is adequate for practical applications.