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If AR smart glasses are to become the ‘next big thing’ and commonplace, their optics must be easier and more affordable to manufacture. Though optics may only be part of a total AR system, it plays a vital role as the window to the world for its wearer. The industry has already set the technical criterion for an acceptable AR optics solution in terms of efficiency and form factor. But the commercial viability of this complex optical product is still challenging. The solution to cost-effectively produce the waveguide combiners, is to switch the manufacturing mindset from a purely semiconductor-based one to one rooted in the realities and learnings of the display industry. We at Morphotonics strive to build the foundation for a future when large-area nanoimprinting can produce AR optical waveguide combiners in display volumes. In this talk, we will address the upscaling process of AR optics manufacturing via large-area nanoimprinting as well as the remaining challenges in terms of performance, materials, and manufacturability. Additionally, we will highlight the exemplary work recently undertaken with our industry partners to validate the entire value chain from design to mastering to replication on panel-level nanoimprint equipment using rectangular high refractive index glass substrates and high refractive index resins.
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