Virtual reality and augmented reality devices require increasingly demanding optical components. Head mounted displays for VR systems often use molded Fresnel lenses, which can be affordably mass produced, maintain low weight, and still achieve high optical performance. Here, we describe an optical system designed for a wide field-of-view, consumer VR headset. Custom tooling was fabricated via diamond turning in order to injection mold the acrylic lenses. Each optical channel is composed of two lenses. The lenses have a spherical-convex surface and an aspheric-convex Fresnel on a spherical-concave surface; the radii of the spherical surfaces differ between the two lenses. Each lens pair relays the image from a compatible smartphone to the eye. To assess the quality of the lenses, the surface finish and surface profiles were measured using a white light interferometer and a contact profilometer, respectively. The lenses were assembled into a custom headset, and their performance was demonstrated via commercial VR software.
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