3D Printing A Cheap VR Headset

October 4, 2025 by Lewin Day 22 Comments

The modern era of virtual reality really kicked off in earnest just over a decade ago, when the Oculus Rift promised 3D worlds beyond your wildest dreams. Since then, nobody’s been able to come up with a killer app to convince even a mild fraction of consumers to engage with the technology. Still, if you’re keen to tinker, you might like to make your own headset like [CNCDan] has done.

The build is based almost entirely on 3D-printed components and parts sourced from AliExpress. It offers 2880x1440p resolution, thanks to a pair of square 1440×1440 LCD displays, one for each eye, paired with a couple of 34 mm lenses. The headset has adjustable interpupiliary distance so you can dial the view in to properly suit your eyes. The 3D-printed housing is designed to be compatible with headrest pads from the HTC Vive Pro for comfort’s sake. Head tracking is also available, with the inclusion of an IMU and an Arduino onboard. [CNCDan] apparently put the build together for under $150, which is not bad compared to the price of a commercial off-the-shelf unit. Files are on Github for the curious.

[CNCDan] reports good results with the DIY headset, using it primarily with his racing simulator setup. He has had some issues, however, with his LCD screens, which don’t properly run at a 90 Hz refresh rate at full resolution, which is frustrating. It’s an issue he’s still looking into. We’ve seen some other neat VR builds over the years, too. Video after the break.

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VR Headset With Custom Face Fitting Gets Even More Custom

September 28, 2024 by Donald Papp 7 Comments

The Bigscreen Beyond is a small and lightweight VR headset that in part achieves its small size and weight by requiring custom fitting based on a facial scan. [Val’s Virtuals] managed to improve fitment even more by redesigning a facial interface and using a 3D scan of one’s own head to fine-tune the result even further. The new designs distribute weight more evenly while also providing an optional flip-up connection.

It may be true that only a minority of people own a Bigscreen Beyond headset, and even fewer of them are willing to DIY their own custom facial interface. But [Val]’s workflow and directions for using Blender to combine a 3D scan of one’s face with his redesigned parts to create a custom-fitted, foam-lined facial interface is good reading, and worth keeping in mind for anyone who designs wearables that could benefit from custom fitting. It’s all spelled out in the project’s documentation — look for the .txt file among the 3D models.

We’ve seen a variety of DIY approaches to VR hardware, from nearly scratch-built headsets to lens experiments, and one thing that’s clear is that better comfort is always an improvement. With newer iPhones able to do 3D scanning and 1:1 scale scanning in general becoming more accessible, we have a feeling we’re going to see more of this DIY approach to ultra-customization.

Hackaday Links: February 18, 2024

February 18, 2024 by Dan Maloney 17 Comments

So it turns out that walking around with $4,000 worth of hardware on your head isn’t quite the peak technology experience that some people thought it would be. We’re talking about the recently released Apple Vision Pro headset, which early adopters are lining up in droves to return. Complaints run the gamut from totally foreseeable episodes of motion sickness to neck pain from supporting the heavy headset. Any eyeglass wearer can certainly attest to even lightweight frames and lenses becoming a burden by the end of the day. We can’t imagine what it would be like to wear a headset like that all day. Ergonomic woes aside, some people are feeling buyer’s remorse thanks to a lack of apps that do anything to justify the hefty price tag. The evidence for a wave of returns is mostly gleaned from social media posts, so it has to be taken with a grain of salt. We wouldn’t expect Apple to be too forthcoming with official return figures, though, so the ultimate proof of uptake will probably be how often you spot one in the wild. Apart from a few cities and only for the next few weeks, we suspect sightings will be few and far between.

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Why VR As Monitor Replacement Is Likely To Be Terrible For A While Yet

August 9, 2023 by Donald Papp 26 Comments

Putting on a headset and using virtual monitors in VR instead of physical ones is a use case that pops up, but is it really something feasible? [Karl Guttag], who has long experience and a deep understanding of the technical challenges that face such devices, doesn’t seem to think so.

In his writeup [Karl] often focuses on the recently-unveiled high resolution Apple Vision Pro, but the issues he discusses transcend any particular product. His article is worth the read for anyone with an interest in these issues, but we’ll summarize some main points here. Continue reading “Why VR As Monitor Replacement Is Likely To Be Terrible For A While Yet” →

Making Your Own VR Headset? Consider This DIY Lens Design

August 1, 2023 by Donald Papp 11 Comments

Lenses are a necessary part of any head-mounted display, but unfortunately, they aren’t always easy to source. Taking them out of an existing headset is one option, but one may wish for a more customized approach, and that’s where [WalkerDev]’s homebrewed “pancake” lenses might come in handy.

Engineering is all about trade-offs, and that’s especially true in VR headset design. Pancake lenses are compact units that rely on polarization to bounce light around internally, resulting in a very compact assembly at the cost of relatively poor light efficiency. That compactness is what [WalkerDev] found attractive, and in the process discovered that stacking two different Fresnel lenses and putting them in a 3D printed housing yielded a very compact pancake-like unit that gave encouraging results.

This project is still in development, and while the original lens assembly is detailed in this build log, there are some potential improvements to be made, so stay tuned if you’re interested in using this design. A DIY headset doesn’t mean you also must DIY the lenses entirely from scratch, and this option seems economical enough to warrant following up.

Want to experiment with mixing and matching optics on your own? Not only has [WalkerDev]’s project shown that off-the-shelf Fresnel lenses can be put to use, it’s in a way good news that phone-based VR is dead. Google shipped over 10 million cardboard headsets and Gear VR sold over 5 million units, which means there are a whole lot of lenses in empty headsets laying around, waiting to be harvested and repurposed.

Closing In On A PC Enabled PSVR2

July 23, 2023 by Donald Papp 25 Comments

When the PlayStation VR2 headset was released, people wondered whether it would be possible to get the headset to work as a PC VR headset. That would mean being able to plug it into a PC and have it work as a VR headset, instead of it only working on a PS5 as Sony intended.

Enthusiasts were initially skeptical and at times despondent about the prospects, but developer [iVRy]’s efforts recently had a breakthrough. A PC-compatible VR2 is looking more likely to happen.

So far [iVRy] is claiming they have 6 DOF SLAM (Simultaneous Localisation and Mapping), Prox sensor, and stereo camera data.

Most of the juicy bits are paywalled behind [iVRy]’s Patreon. We’re hoping the jailbreak process will eventually be open-sourced.

The PS VR2 headset is quite unlike a PC VR headset in a number of ways, and it has not been historically easy to work with Sony’s products from a reverse-engineering perspective, whether it’s an attempt to improve the user experience of an annoying headset, or an attempt to understand the not-even-remotely-sanely-designed protocols behind the Sony Memory Stick. Getting the PS VR2 headset to work in a way it wasn’t intended was expected to be an uphill battle.

It’s not a finished job, but judging by the progress regularly shared on [iVRy]’s Twitter account, it might only be a matter of time.

Behold A Gallery Of Sony’s PS VR2 Prototypes

July 22, 2023 by Donald Papp 3 Comments

Every finished product stands at the end of a long line of prototypes, and Sony have recently shared an interview and images of their PlayStation VR2 prototypes.

Many of the prototypes focus on a specific functionality, and readers who are not familiar with building things might find it a bit wild to see just how big and ungainly un-optimized hardware can be.

Finished product (bottom) contrasted with functionally-identical prototype (top).

The images are definitely the best part of that link, but the interview has a few interesting bits. For example, one prototype was optimized for evaluating and testing camera placement with a high degree of accuracy, and it hardly looks like a VR headset at all.

The controllers on the other hand seem to have gone though more iterations based on the ergonomics and physical layout of controls. The VR2 controllers integrate the adaptive triggers from the PlayStation 5, which are of a genuinely clever design capable of variable resistance as well as an active force feedback effect that’s not quite like anything that’s come before.

There’s a lot of work that goes into developing something like a VR headset, as we see here and we’ve seen with Facebook’s (now Meta) VR research prototypes. But even when one can leverage pre-made modules as much as possible and doesn’t need to start entirely from scratch, making a VR headset remains a whole heap of work.