Meta Outlines Strategy for Major Cost Reductions in Next-gen AR’s Key Component

Meta’s ambitious Orion AR glasses prototype is hitting headlines not just for its groundbreaking technology but also for its staggering price tag—each pair costs around $10,000 to produce. The hefty price mainly stems from its custom silicon carbide waveguide lenses. Yet, Meta is optimistic about finding ways to slash these costs in the near future.

Silicon carbide isn’t exactly a new kid on the block. It’s been a go-to material for high-power chips, thanks to its superior power efficiency and reduced heat output. However, crafting silicon carbide isn’t a walk in the park due to its intricate material properties, crystal growth difficulty, and complex manufacturing process.

Interestingly, electric vehicles (EVs) are spearheading efforts to bring down these costs, though achieving a price comparable to cheaper, silicon-based alternatives is still a pipe dream. Silicon carbide might also find a place in quantum computing, although that presents an entirely different set of challenges from what Meta aims to tackle with their next-generation materials.

The allure of silicon carbide for Meta isn’t just about its power or heat traits. What really excites them is its high refractive index, essential for creating clear, wide field-of-view (FOV) waveguides. This material is capable of delivering an impressive 70-degree FOV in the Orion glasses—head and shoulders above conventional multi-layered glass waveguides. For those lucky few who’ve experienced it, switching from standard glass waveguides to Meta’s silicon carbide ones feels like a transformation, shifting from a distracting light show to a serene, immersive symphony.

Optical Scientist Pasqual Rivera described this change eloquently. He likened the old glasses with glass-based waveguides to being in a disco—distracting light everywhere, overshadowing the AR experience. In contrast, the new silicon carbide waveguides offer clarity and focus, allowing users to fully engage with the AR content. It’s like swapping the noise of a party for the tranquility of a classical concert.

In recent years, major players in the EV sector have embraced silicon carbide-based chips, which has started to drive prices down. Giuseppe Calafiore, Reality Labs’ AR Waveguides Tech Lead, points out that the EV industry’s excess supply is now benefiting Meta’s advancements. As supply outstrips demand, the costs for the silicon carbide substrate are falling.

Still, there’s a hitch: the silicon carbide used in EVs isn’t suitable for optics, as it’s optimized for electrical rather than optical performance. This means scavenging surplus from EV chip production isn’t an option for Meta. Nevertheless, Reality Labs’ Barry Silverstein remains optimistic. He believes there’s a path forward as suppliers are thrilled about the potential market for optical-grade silicon carbide. The transition is challenging, with larger wafer sizes like eight-inch and potentially even 12-inch on the horizon, promising to produce significantly more AR glasses at lower costs.

“The world is beginning to understand the versatility of silicon carbide,” Silverstein emphasizes. It’s a material that could extend its reach beyond electronics into photonics and potentially quantum computing. Though there’s much work to be done, the prospects are enormous.

This isn’t the first time an XR headset has reaped the benefits of innovations in larger industries. Back in the early 2010s, affordable display tech developed for smartphones helped ignite the consumer VR headset market. Consider the Oculus Rift DK2 from 2014, which utilized a Galaxy Note 3 display panel, complete with Samsung branding.

Over the years, XR headsets have adopted numerous components from the smartphone realm, including sensors and battery tech. However, leveraging silicon carbide—propelled by the EV boom—for AR glasses presents unique challenges that aren’t so easily navigated.

As suppliers turn toward photonics-grade silicon carbide, they’re entering a highly specialized niche. This is a crucial reason why Meta hasn’t yet launched a consumer version of Orion. However, they’re treating Orion as an internal developer kit, with hopes of introducing consumer-grade AR glasses shortly before 2030. According to CTO Andrew Bosworth, these could eventually be priced more akin to laptops or smartphones.

With the stakes high and the allure of widespread consumer appeal undeniable, these developments are bound to come together. Major tech players like Meta, Apple, Google, Microsoft, and Qualcomm are all vying for a piece of what could replace smartphones as the next leading mobile computing platform.