aci, Military spec VR headset

Engaged in the creation of a VR headset tailored for US military troop training, our focus on the enclosure design, specifically for a high-spec optic system for VR display. Our approach involves the development of a sleek and functional two-piece injection-molded design, ensuring both style and precision.

Close up VR Headset Render by Flynn Design

About the Project

Product Design | Prototype Design | Design for Manufacture
VR Headset


We were involved in the development of an enclosure for very high specification wide field of view optics as part of a virtual-reality training system. The internal workings for the clutch system, which allowed the user to adjust the unit to the optimal position, had been specified before hand and our task was to rapidly develop concept styling and a two piece injection molded enclosure dealing with this awkward geometry and delivering a unique product styling.


We tested various plastics for the enclosure and ended up with a Polycarbonate blend being specified for its molding ease, its durability particularly to shock and abrasion. In order to design the eye cups we had a 3D scan produced of users head (aggregated from the control group). The material we specified for the eye cups was medical grade silicone, which were initially vacuum cast in ABS molds to test fitment to a control group. The client required working prototypes for a photoshoot and tradeshow within 3 weeks of our initial consultation. Needless to say we delivered on time and on budget.

Final Thoughts

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