Magic Leap One Lightwear Augmented Reality Headset

The highly anticipated Magic Leap One delivers an exciting mixed reality world where digital objects are aware of and interact with the real-world environment. The Lightwear headset, which also needed to be easy to wear and adjust to various head sizes, hosts a complicated suite of sensors, cameras, speakers, and optical relay that work together to provide the feedback and data necessary to create the augmented reality experience.

Tact provided 3D CAD sculpting, Class A surfacing, and structural analysis for the Magic Leap One Lightwear headset. We took on the time-consuming CAD surfacing tasks to lighten the Magic Leap Engineering team’s workload and created geometry to match the design intent of the Industrial Designers. Tact also performed a structural analysis on parts that Magic Leap was considering changing from a metal to a lighter weight plastic. As part of the analysis, we verified load and stress distribution, defined thicknesses and determined design constraints for the parts in various materials.