8K VR Headset for Sports

A company specializing in XR and VR business solutions approached EnCata for MVP development services. They needed a compact headset for active physical scenarios, most notably virtual football. The key requirements were 8K resolution, minimal weight, compact dimensions, and stable, predictable performance in challenging operating conditions.

The team developed the device strictly within the approved industrial design. The headset’s size could not exceed that of competitors, which restricted layout freedom and influenced every engineering decision – from enclosure design to video pipeline architecture to the cooling and anti-fog systems.

The project scope covered the complete cycle of device development – from concept to a fully functional prototype. The engineers were tasked with designing the hardware and mechanical parts, ensuring compatibility of all major components, and developing the enclosure. They also assembled a working prototype for comprehensive testing and delivered a complete technical documentation package required for further production and product support.

System architecture

The engineering team defined the device architecture, which included a central microcontroller, an FPGA module for video processing, cameras, displays, a power supply, sensors, and actuators. This architecture made it possible to distribute workload across modules and ensure parallel operation of all subsystems. A schematic diagram illustrated the internal system connections.

First layout and flex cable design

At an early stage, mechanical engineers created the first layout of the headset based on the client’s industrial design. The device had to be more compact than competing models. The team worked within these strict limits, which required very dense placement of electronic and mechanical components and became a critical constraint during development.

Electronics engineers began designing the main control board and selecting rigid-flex cables capable of transmitting stable video signals to 8K 90 Hz displays. To quickly validate core functions, available off-the-shelf options were used, which allowed the team to confirm image output and IPD adjustment early on. However, it quickly became clear that the stiffness of six-layer cables overloaded connectors and required stronger motors to move the lenses.

Cable refinement and connector fixation

The engineers redesigned the flex cables, reducing the number of layers from six to four. This gave the assembly the required flexibility and ensured a bending radius of R10.48 mm. We also re-routed the cables to minimize bending loads during lens movement and introduced stiffeners to reinforce the connectors.

As the next step, we replaced the connectors with more reliable lock-type versions. They kept the stiffeners in place and reworked them for even greater robustness. Combining both solutions guaranteed stable operation even under active movements and vibration.

In parallel, more powerful actuators were installed. Although this slightly increased the headset’s weight, the change stayed within acceptable limits and provided the torque needed to compensate for resistance during lens adjustments.

Enclosure and optical system

At the same stage, the engineers developed the enclosure and optical system. The control board was mounted to the enclosure using thrust elements, allowing removal after detaching the visor. This solution gave quick access to the electronics, simplified upgrades, and reduced servicing time.

Guides and IPD mechanism

Interpupillary distance was identified as a critical ergonomic parameter. The team used NASA’s open data (54-74 mm) and consumer standards from Valve Index and Pimax, adopting ±1 mm accuracy as the design goal.

The first prototype used one large guide per display. Although this simplified the mechanism and reduced weight, testing showed about 2 mm of play – outside the required tolerance.

We switched to two lightweight guides, one per display. This reduced the play to 1 mm, distributed load more evenly, and provided rigid fixation, without increasing overall mass.

Drive system

Instead of a central gearbox, two independent actuators were installed. This solution enabled individual IPD adjustment and compensated for minor asymmetries in users’ eye positions, which was critical for visual comfort in XR applications.

Face mask

The face mask was developed as a separate design track. Our team chose silicone as the optimal material: it provided an aesthetic form, was food-grade and biocompatible, ensured a tight seal without irritation, and resisted chemical degradation during disinfection.

Samples with hardness ranging from 5 to 30 Shore A were evaluated for user perception and appearance. The best result was 10 Shore A, which balanced softness, comfort, and mechanical stability.

We developed a magnetic mounting system. It allows the mask to be quickly removed and replaced. This simplifies cleaning (especially important in sports training, where hygiene and easy servicing are essential).

The molds for silicone casting were produced using FDM 3D printing with surface post-processing. SLA printing was avoided, since platinum-cure silicone does not set in contact with photopolymers. Because of the complex geometry, the mold parting lines required manual finishing.

Positioning system

The positioning system was based on the Alt infrared camera module with its own processing unit. This choice eliminated the need to design custom algorithms or add separate motion sensors, which saved prototype development time and reduced costs. Placement was carefully chosen so that the user’s face and hands would not interfere with tracking.

FPGA and video pipeline

Image output was implemented on an FPGA (Field-Programmable Gate Array). This ensured the performance required for high-speed video streams and the non-standard display setup.

The FPGA supported DisplayPort 1.4a and USB-C, enabling compressed video transmission at 8K 90 Hz. The stream was divided between two displays. Alternatives such as video processors were too large and costly, while microcontrollers lacked sufficient bandwidth.

The engineers configured video output and integrated it with SteamVR. Logical routing was implemented with consideration for display interfaces. Since no off-the-shelf solution existed, the team created a second virtual desktop, developed a custom driver, and demonstrated the prototype with a PlayStation gamepad, as controllers of other headsets were locked to their ecosystems.

Anti-fog system

Lens fogging was addressed as a separate task. Several approaches were tested to achieve reliable results. 

In the first version, a fan was placed on the board, but testing revealed unacceptable noise due to both the fan itself and its location.

In the refined design, a more efficient and quieter fan was selected, and airflow was re-engineered. The fan was integrated into the external enclosure, directing air precisely onto the lens surfaces.

This solution provided reliable anti-fog protection, met the client’s requirements for the first prototype, and allowed testing to continue without further changes.

The project confirmed that an 8K video system can be integrated into a compact wearable enclosure and still deliver stable performance. This proved that even high-performance, architecturally complex boards can function reliably in small, lightweight devices.

As a result, the face mask geometry was finalized, the control board layout refined, and new IPD adjustment motors tested.

The headset successfully launched in SteamVR, delivered 8K video output, demonstrated stable mechanics, withstood operational loads on flex connections, and featured a housing that allowed rapid replacement of critical components (essential for sports use and pilot production).