Tactical Augmented Reality Headset
Mechanical design and prototype delivery for a tactical AR headset with waveguide optics
Overview
The Ravn HUD project involved designing an AR headset system with waveguide optics tailored for tactical use. Amoung several challanging important constraints was the requirement that the headset fit behind night vision goggles (NVGs). I provided the mechanical design, prototyped several headsets, and collaborated closely with optical and electrical engineers to deliver an electromechanical architecture that balanced optical performance and soldier ergonomics.
For early prototypes, I personally fabricated polycarbonate lenses that held an off-the-shelf waveguide. This included machinging and polishing the pocket that held the waveguide, precisely bending the polycarbonate lense, and then performing secondary machine operations to produce the final lens geometry. For the polishing step, I designed and 3D printed a custom tool and programmed the CNC to polish the lens.
Later on, I worked with the optical engineer and the vendor to produce a custom waveguide with our lens profile. This waveguide was used in the frames that I designed and was delivered to SOCOM as part of a contract.
Several different early prototypes of the headset.
Mid-stage development assembly, built to support software development.
Cutting lens blanks for bending and machining.
Lens polishing using a custom 3D printed tool.
3D printed fixtures for custom polycarbonate lenses.
Functional prototype using polycarbonate lenses and off-the-shelf waveguide.
Internal view of deliverable version with custom electronics and waveguide lens profile.
Headset paired with Control Pack V1 for SOCOM delivery.
Contract deliverable unit featuring the tactical headset, Control Pack V1, and Rail Mounted Controller and supporting hardware.
Accomplishments
- ✓Designed the mechanical architecture for the tactical headset, integrating optics, electronic packaging, and night vision compatibility.
- ✓Collaborated across disciplines to define electromechanical interfaces that aligned optical components, displays, and electronics.
- ✓Built multiple functional prototypes internally and delivered a refined prototype to SOCOM.
Lessons Learned
- •Close collaboration with optics engineers is essential; window placement and optical path constraints must shape the mechanical geometry.
- •Optical engineering is incredibly complex.
- •Designing for compatibility with existing equipment requires observing actual user workflows.