The client, an XR solution development company, required an MVP for a next-generation VR headset focused on virtual sports training (e.g., football). The main challenge was the necessity to integrate 8K resolution displays running at 90 Hz into an enclosure that had to be more compact and lighter than existing market leaders (such as Meta Quest 3). Additionally, we had to ensure stability during active use and highly precise Interpupillary Distance (IPD) adjustment, with a tolerance of just ±1 mm.

Our team executed the full development cycle (from concept to prototype, TRL 2 → 7), focusing on overcoming critical engineering limitations: 1. Stable 8K Signal: We re-engineered the rigid six-layer flexible cables to a more flexible four-layer design and incorporated stiffeners with lock-type connectors. This guaranteed stable 8K/90Hz video signal transmission even with lens movement. 2. High-Precision IPD: To achieve the ±1 mm accuracy, we designed a mechanism using two lightweight guides per display, coupled with two independent actuators. This eliminated play and allowed for precise, individual IPD adjustment. 3. System Integration: We utilized an FPGA-based architecture for video processing and developed a custom driver for seamless integration with SteamVR. An integrated anti-fog system with optimized airflow was also implemented.

The project was successfully completed in just 8 months. The client received a working prototype ready for pilot production, confirming: - Technical Performance: Successful integration of 8K resolution and a 90–110° field of view into a compact wearable form factor. - Business Value: The project proved the feasibility of creating a high-performance product, giving the client a significant competitive advantage in the sports simulation market.