Meta Outlines Strategy for Major Cost Reduction in Key Component of Next-Gen AR

Creating the Orion AR glasses prototype has proven to be quite the financial feat for Meta, with a staggering price tag of roughly $10,000 per pair. The most financially demanding element of this groundbreaking technology is undoubtedly the custom silicon carbide waveguide lenses. However, Meta is optimistic about their ability to significantly curb these costs in the near future.

Silicon carbide isn’t a newcomer to the tech scene; it’s been a staple primarily in the realm of high-power chips, thanks to its superior power efficiency and lower heat emission. But this material is notoriously tricky to produce, a challenge compounded by its inherent material characteristics, intricate crystal growth, and complex fabrication processes.

Interestingly, the electric vehicle industry is spearheading efforts to lower these costs, though reaching the affordability of silicon-based alternatives is still a distant milestone. Future applications also hint at its potential role in quantum computing, albeit that path presents its own set of hurdles, distinct from Meta’s current goals for this next-gen material.

But what draws Meta’s attention is not just the power efficiency; rather, it’s the material’s impressive refractive index. This makes it perfect for crafting clear and expansive field-of-view (FOV) waveguides for their AR glasses, boasting a 70-degree FOV that’s setting a new benchmark with Orion. The difference in clarity between traditional multi-layered glass waveguides and those made from silicon carbide is striking, offering an experience akin to switching from a cluttered disco to a serene symphony.

Meta’s Optical Scientist, Pasqual Rivera, captures this transition vividly, saying, “With glass-based waveguides, everything felt like a chaotic disco—distractions everywhere. But with silicon carbide waveguides, it’s like attending a peaceful orchestral session. The AR experience is wholly transformative.”

The last few years have seen a trend among leading electric vehicle manufacturers towards silicon carbide-based chips, which is progressively driving costs downward. Giuseppe Calafiore from Meta’s Reality Labs pointed out that the increased supply due to the EV market’s overcapacity is contributing to a fall in substrate prices.

It’s important to note, though, that EV-utilized silicon carbide wafers aren’t designed for optical use. They prioritize electrical functionality, making adaptation for AR optics impractical. Nonetheless, Barry Silverstein, Meta’s Research Science Director, sees an opportunity on the horizon. He explains, “Suppliers are eager about manufacturing optical-grade silicon carbide. With larger manufacturing capabilities, the potential for cost reduction is significant. Larger wafers mean lower costs, even as the process complexity grows. We’ve observed progress from four-inch to eight-inch wafers, and discussions of even larger 12-inch versions are underway, promising more AR glass pairs per production batch.”

Silverstein adds, “Now is the moment of awakening. Silicon carbide is showcasing its versatility across electronics and photonics, with burgeoning possibilities in quantum computing. We are witnessing tangible signs that costs could drop significantly. Plenty of work remains, but the potential benefits are immense.”

This isn’t the first time XR technology has benefited from wider industry trends. Smartphone displays played a pivotal role in the VR headset emergence, with devices like the Oculus Rift DK2 incorporating panels straight out of Samsung’s Galaxy Note 3.

Smartphones have long lent components to XR development, from IMUs to camera sensors and battery technology. Yet, replicating these outcomes with the current momentum of silicon carbide remains considerably more complex for the AR glasses sector.

Though suppliers are eyeing photonics-grade silicon carbide, scaling it remains a niche goal that will take several more years. This challenge is among the key reasons Meta hasn’t yet commercialized Orion. For now, Meta views Orion as an “internal developer kit” while aiming for consumer AR glasses by the end of the decade, priced comparably to current laptops or phones, as per CTO Andrew Bosworth’s insights.

Despite the difficulties, integrating these components presents an enticing opportunity. Major tech players like Meta, Apple, Google, Microsoft, and Qualcomm are all strategically positioning themselves to capture segments of the emergent mobile computing landscape set to redefine how we interact beyond smartphones.