Pancake Lenses through Curved Lamination for Compact Virtual Reality

The pancake optical system, which reduces optical thickness by folding the optical path through polarization elements, emerges as the leading solution for virtual reality displays. As manufacturing technologies evolve and consumer demand for higher image quality grows, pancake systems transition from flat to curved-laminate configurations. This article analyzes the advantages of pancake systems incorporating curved-laminated lenses over those employing conventional flat-laminated lenses, with respect to form factor, imaging quality, and other aspects of optical performance. Both designs deliver an 8 mm exit pupil diameter, 15 mm eye relief, and a 105° field of view (FOV). The curved-laminated system demonstrates higher image uniformity than conventional designs, with RMS spot diameters below two-pixel dimensions across the field. Subsequent optimization expanded its FOV to 110° while RMS spot diameters consistently below 14.5 (Formula presented.). Finally, a binocular prototype based on the design is fabricated, demonstrating exceptional visual clarity and accurate color reproduction.