VR headset



Link to Thingiver:


  • Design Concept

Recently I am learning Unity, an software the world’s leading real-time engine, is used to create half of the world’s games. Unity can also be used to create VR experience. Technology makes the virtual world blend with the real world and makes people’s life more colorful. The development of virtual reality technology greatly expands people’s vision and enables people to experience a richer world. As a head-mounted display device connecting the virtual world, VR glasses have witnessed explosive growth with the trend of virtual reality technology. This time i go back to my previous idea of 3d printing VR headset. For the first project, I didn’t have enough time to finish the vr headset.

Background of VR headset design:

Now, people are familiar with VR glasses, and they are full of expectations for future VR glasses design. After a long time of brewing and development, VR glasses design has penetrated into games, online shopping, movies, music and other fields, and has produced a wide range of influence, and is deeply loved by users. VR glasses allow people to enjoy the fun that is not available in the real world. As long as they wear them, they can enter the virtual world designed by them through relevant software. For example, with VR glasses in games, players can really enter the game world and feel like they are in the mirror instead of watching 2D animation. For gamers, VR glasses are a must-have weapon. Another example is online shopping. Through VR glasses, users can enter a virtual store designed by the merchant, view the goods in close range, try them on, and provide real purchasing experience for users.

Use more in line with people’s living habits. In order to let people have a more intuitive understanding of the product, VR glasses attach great importance to the sense of technology and future of the product in the appearance design, give people a sense of cool technology visually, and better show the semantic function of VR glasses. Although VR glasses design is still in the primary stage of development, and the popularization scope is not large, the great vitality and benefits it shows are obvious to all. With the advent of the virtual reality era, VR glasses will inevitably rise in popularity and have a profound impact on people’s lives.

The benefit of 3D printing headset:

  1. Lightweight:it is easy to carry around.
  2. Personalized:we need to pay attention to the size of the phone that VR glasses fit into — although the compatibility is very strong, but the screen size is wrong, there is no way to fit it. the VR headset is primarily for mobile phone users. One problem is that apple doesn’t have official version VR headset. And the size of the mobile phone is different, if we can take advantage of the printer, we can be customized VR headset for different mobile phone.


  • Objective


This is the final assignment, we will develop a project using a combination of digital and traditional fabrication methods. I want to take design challenge from my previous assignment making a VR headset. I had some experience of Illustration so I feel comfortable with laser cutting. So I want to spend more time on exploring the possibility of 3D printing and an open source project online. This time I go back to my previous idea of 3d printing VR headset. For the first project, I didn’t have enough time to finish the VR headset.

Object 1: Increase users’ experience and design a VR headset work for iphone 8 plus.

VR glasses designed for phone users have limited effects. At the same time, they are not picky about the performance of smartphones. The android and iOS systems are accepted according to the order, and the only thing they need is the phone’s gyroscope (gravity sensing) function. So my first object for this project is to design a headset work for iphone 8 plus.

Object 2: To ensure the accurate recreation of your product, test and improve the design.

In order to design a successful glasses, we need to deeply investigate the imaging principle of vr glasses, such as the distance between the lens and the screen, so as to give users clear imaging and better visual effect experience.


  • Challenges


  • Iterative design process


Work left from first project:

I designed a milk tea cup in first assignment. I ignore the fact that material 3d printing used are not food safe. It was an exploration printing the cup, but less practical considering how many 3D printed filaments are not food safe. I should have researched more on that. So I want to go back to my previous idea of 3d printing VR headset. I wanted to design a personal VR headset first. Since Apple VR headset doesn’t exist yet, there is a breed of headsets that are created by third party. There are a lot of options out there, but still cannot find a good one? Some VR headset made of cardboard are really cheap, which are so easy to break. Some VR well-designed headset but still not perfect fit your head. Without a good fit on your head your VR experience won’t be too enjoyable at home. I want to have a 3D printing customize VR headset made just for you. The biggest highlight of the headset is the enhanced comfort 3D printing technology can offer. That means, the headset is designed based on the shape of your head. Customer can also design the look and color of the headset and make it more personalize. Before I used 360 Fusion, I used tinkercad to have the basic idea of the VR headset. I divided the headset into two parts: top and bottom.



  1. Limited time: I spent my first week on tutorials and the concept. Then I started to design the headset on the last week before the due. Maker lab is closed on Friday. That is to say, I have to have the stl file before Wednesday or Thursday.
  2. Optical design: The core thing is whether the VR glasses lens design is reasonable. The visual Angle, focal length and optical parameter design of VR glasses are reasonable or not, and the material is reasonable or not. It is directly related to the visual Angle, focal length, video deformation, vertigo, and the size and light design of the body. So I think I have to a cardboard VR set and the take out the glasses.
  3. Software design:
  4. Measurement: I’d like to know how much difference can the design of headset shape change the comfort of wearing and influence VR experience. I also want to know the best way to measure the size and shape of people’s head.
  5. The most challenging thing is: when I finished the bottom, I don’t know what to do with the top. It is really hard to measure the size.


Design Process: 

Step 1: measuring size


At first, I only paid attention to measuring the size of the mobile phone, and then I found that the size of the mobile phone was not the most critical, and the display screen of the mobile phone was the key to the virtual reality experience.


So I designed the outer shape of the headset based on the size of phone.


Step 2: Design in Tinkercad

Create a solid box:


Use two roof to cut the shape of headset:


(Change those roofs from solid to hole)


(Select all and group)

Create outer shape of the VR headset.


(Copy and paste)


(Size down to create inner shell)


(Select all and group)

Create two rings to tie the VR headset on user’s head.


(Use two torus)


(Select all and group)

Create the space for phone:

screen-shot-2019-02-09-at-12-01-05-pm screen-shot-2019-02-09-at-12-01-40-pm

Create the round shape of the case:



Create space for eyes and nose:



Add the logo:


Download as stl


Open the stl file with cura:


It says “unable to slice” because I used the wrong printer setting. I used mini, which is very small. I cannot print this VR headset using this type of printer.


After I changed the settings, it work.



Choose the right material is very important. It is going to take 10 hours to print the VR headset.

  • Tools & Materials used

Software: Tinkercad and cura

Useful shortcuts:

D: down

Ctrl + G: Group

Hardware: 3D printer


  • Relevant research