Pancake Lenses

Avantier’s Pancake Lens is an advanced optical solution designed for next-generation Virtual Reality (VR) headsets. Featuring a folded optical path structure, the Pancake lenses enable thinner, lighter, and more immersive head-mounted displays by integrating reflective polarizing films and quarter-wave plates.

This lens is engineered to meet the demanding requirements of modern VR optics, delivering enhanced image clarity, optimized space usage, and unparalleled miniaturization.

Key Features

Folded Optical Path Design
Utilizes multiple internal reflections to achieve a compact structure while maintaining excellent image quality.
Miniaturization
- Reduces optical thickness by 60–70%
- Cuts headset weight by 30–40%
- Shortens the distance between the display and the lens
Enhanced Image Performance
- Multi-lens combination corrects distortion and chromatic aberration
- Clearer edge details and improved contrast
Efficient Space Utilization
Frees up interior space for sensors, batteries, and additional modules in VR devices.

The working principle of Pancake structure

The Pancake structure combines a reflective polarizing film, quarter-wave plate, and semi-reflective mirror to fold the optical path efficiently. Light transmission involves:

Conversion between circularly and linearly polarized light
Strategic internal reflections
Effective stray light suppression
Optimized light transmittance to the user’s eye

This configuration enables a compact optical path while maintaining visual accuracy and brightness.

Applications

Virtual Reality Headsets
Folded Optical Systems in Augmented Reality (AR) Windshields
Curved Head-Up Displays (HUDs)

Manufacturing Capability: Polarizing Film Lamination

The lamination process plays a vital role in Pancake lens performance. It involves adhering a polarizing film and quarter-wave plate onto curved lens surfaces with extreme precision.

Technical Highlights:

Optical axis tolerance: ±0.5°
Surface shape accuracy: PV < 2 fringes @ 633 nm
Visual inspection pass rate: ≥99.5%

Process Innovations:

High-precision vacuum laminating (±1 µm)
Low-modulus optical adhesives (≤3 MPa)
Advanced visual alignment systems

Case Study

Lens Type: Convex-concave H-K9L
Diameter: Φ42 mm | Radius: 130 mm
Lamination: Polarizing film on convex surface

Results:

100% cosmetic quality
Surface deviation: PV = 1.8 fringes
Transmittance deviation: <1% (400–700 nm)
Polarization degree: >99.5%
Optical axis deviation: 0.3°

Future Outlook for Pancake Lenses

As VR devices trend toward thinner profiles (<30 mm) and wider fields of view (>150°), our Pancake Lens technology is advancing to meet new challenges:

Nanoscale precision bonding for freeform surfaces
Machine vision with AI for automated defect detection
Innovative materials: flexible polarizers and stretchable adhesives

Partner with Avantier to unlock the full potential of lightweight VR with our industry-leading Pancake Lenses technology and precision lamination capabilities. We are committed to supporting high-volume production with exceptional optical quality, helping bring VR from premium experiences to everyday accessibility.

Ready to integrate next-gen optics into your VR system?
Contact us today to learn more about our customizable Pancake Lens solutions.