As anyone who’s tried on the Apple Vision Pro for more than 15 minutes knows, it is a heavy headset that presses uncomfortably against the face.
Task
Create a replacement LightSeal that fits my actual face structure, seals out stray light, and still fits perfectly into the Vision Pro frame.
Action
Captured a high-resolution scan of my face with Scandy Pro on an iPhone
Found a reference Apple Vision Pro model online and aligned it with my face digitally
Rebuilt the contact surface in Blender around my face structure
Extended the surface outward to merge into existing LightSeal edge to have a perfect fit
Printed the new model on an Ender 3 3D printer
Result
The fit was actually perfect on the first try, both in the Vision Pro frame and against my face. However, it wasn’t enough to offset the weight of the headset, as it’s simply a really heavy device. I still consider it a success, given how well everything lined up and how effective the face scan and modeling process went!
