A manufacturing-oriented optical design: achieving high performance in head-mounted displays with a single freeform combiner

This paper presents a manufacturing-oriented optical architecture for head-mounted displays (HMDs) using a single freeform surface. While multi-freeform systems achieve high performance, they introduce fabrication and alignment complexities. We demonstrate that a strategically optimized single freeform element can meet key benchmarks—a 20° field of view, MTF > 0.1 at 30 lp/mm, and distortion < 5%—while offering simpler assembly, relaxed tolerances, and lower cost. We detail the Gaussian Radial Basis Function formulation with 76 nodes, optimization constraints, and a comprehensive tolerance analysis. A quantitative comparison highlights reduced complexity and alignment sensitivity versus multi-surface designs. This simulation-based study provides a validated design framework; experimental validation remains future work. Deliberate architectural minimalism, supported by rigorous surface engineering, offers a viable pathway for compact, high-performance, manufacturable HMD optics.