It has always been a challenge to break the resolution/field-of-view (FOV) invariant to design a large FOV and high-resolution optical system, especially for a head-mounted display (HMD) system. In this study, a tiled HMD using two compact rotationally symmetrical eyepieces was designed and developed. Some issues on exit pupil and eye relief were analyzed in detail and taken into consideration during the design procedure. The overall optical system is compact with high performance. The system volume is smaller than 30  mm×35  mm×30  mm. Based on two 0.61 in. microdisplay devices, the overall tiled system demonstrates an FOV of 66°(H)×32°(V) with a 7.5 mm exit pupil diameter and a 15.7 mm eye relief.

As a kind of light-weighted and convenient tool to achieve stereoscopic vision, virtual reality glasses are gaining more popularity nowadays. For these glasses, molded plastic lenses are often adopted to handle both the imaging property and the cost of massive production. However, the as-built performance of the glass depends on both the optical design and the injection molding process, and maintaining the profile of the lens during injection molding process presents particular challenges. In this paper, optical design is combined with processing simulation analysis to obtain a design result suitable for injection molding. Based on the design and analysis results, different experiments are done using high-quality equipment to optimize the process parameters of injection molding. Finally, a single concave-convex lens is designed with a field-of-view of 90° for the virtual reality 3D glasses. The as-built profile error of the glass lens is controlled within 5μm, which indicates that the designed shape of the lens is fairly realized and the designed optical performance can thus be achieved.