AR displays @ Meta

Danny wearing a pair of Orion glasses

I’ve spent >7 years at Meta Real Labs working on nearly every aspect of AR displays, culminating in Orion, Meta Ray Ban Display, and other yet-to-be-revealed AR glasses devices.

Over the years, this has given me a breadth of experience with everything going into AR display systems.

I have worked hands-on with the system integration of and demos of complete head-mounted systems with every piece of the puzzle:
– uLED, LCoS, DLP, and laser beam scanning light engines (incl. backplanes, illumination, projection optics, active alignment, STOP analysis)
– diffractive and reflective waveguides
– ophthalmic (RX) lenses
– binocular disparity sensor
– eye tracking illuminators, combiners, and cameras
– electrochromic and photochromic dimming
– integration of the above components into modules and systems
– optical metrology equipment and methods
– geometric and photometric calibration
– perceptual evaluation and metrics

This experience allowed me to:
– create a lauded AR display 101 seminar to create a cohesive narrative for non-optics experts
– lead demos for the AR display org
– create design guidelines for how to accommodate the novel aspects of additive displays

I have invented:
– novel approaches for dynamically trading color gamut for power (brightness/battery life)
– a new integration strategy for custom ophthalmic (RX) lenses
– new use cases unlocked with AR displays

Examples of head-mounted display system demonstrators I have worked on – precursors to Orion
Meta Orion glasses
uLED display module
Display projector assembly
Silicon carbide waveguide wafer
Diced waveguide subassembly
Eye tracking illuminators + combiner
Example of benchtop optical systems I have worked on

Product design @ Microsoft Surface

My first job was at Microsoft designing, integrating, and developing electro-mechanical and opto-mechanical subsystems for Surface Book 2, Surface Book, and Surface Pro 3 devices. My designs have been in millions of devices, and I’ve had 15+ trips to suppliers in Asia, so I know what it takes to ship hardware!

  • Camera modules, IR illumination systems, light pipes, audio modules (speakers & microphones), Touch Display Modules (TDMs), Flexible Printed Circuits (FPCs)
  • Stamped sheet metal parts, injection-molded plastics, compression-molded elastomers, die cut foams and adhesives
  • Drove suppliers in Asia to develop and integrate modules
Surface Book 13.5″ (left to right) ambient light sensor (ALS) with novel interposer design (not shown: micro-hole array), infrared (IR) illumination LED (not shown: my patented self-registering condensation lens!), IR camera, RGB camera, privacy LED (not shown: injection molded light pipe), front mic boot, accelerometer
Surface Book 13.5″ rear facing auto-focus camera module w/rear privacy LED + injection molded light pipe + rear mic boot
Surface Book 13.5″ speaker modules + RF antenna shielding + grounding + meshes

Surface Book 15″ cameras, sensors, speakers, fans, vapor chamber, graphite heat spreaders, and associated diecut + stamped components
Surface Pro 3 Touch Display Module (TDM), magnets, and associated diecut components