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Wide field of view multiplexed

photopolymer consumer AR displays

Jonathan Waldern, Alastair Grant, Milan Popovich

Jonathan D. Waldern, Alastair J. Grant, Milan M. Popovich, "Wide field of view

multiplexed photopolymer consumer AR displays," Proc. SPIE 11310, Optical
Architectures for Displays and Sensing in Augmented, Virtual, and Mixed
Reality (AR, VR, MR), 113100I (19 February 2020); doi: 10.1117/12.2551872

Event: SPIE AR VR MR, 2020, San Francisco, California, United States

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 Wide field of view multiplexed photopolymer consumer AR displays
Jonathan D. Waldern. Alastair J. Grant, Milan M. Popovich
DigiLens, Inc., 1288 Hammerwood Ave, Sunnyvale, CA 94089, USA

ABSTRACT

Wide field of view color waveguide display reference designs for low-cost consumer AR displays using high index
modulation photopolymer and liquid crystal material for providing compact wide-angle, displays are presented.

Keywords: Diffractive optics, switchable gratings, augmented reality, AR, wearable displays, liquid crystal, holography;
waveguide; head-up display; optics).

1. INTRODUCTION

Delivering wide field-of-view (FoV) color, daylight-compatible brightness and ultra-compact form factors at an
acceptable price presents major development hurdles for consumer AR displays1. The form factor challenge is only
partially met using thin waveguides; current picture generation units, comprising the microdisplay beam splitter and
projection optics, are increasingly seen as too bulky to satisfy the aesthetic requirements of consumer eyewear, while
traditional input, fold and output grating architectures occupy too much waveguide real estate. Brightness and power
consumption are compromised by the inefficiencies of current solutions for coupling light from a picoprojector into a
waveguide (typically incurring 95% loss). Lasers now offer a commercially viable solution for enhancing color and
brightness but bring new problems: speckle and other illumination non-uniformities. This paper reviews developments
by DigiLens directed at a compact wide angle, full color laser illuminated consumer AR waveguide. DigiLens is
prototyping a novel Integrated Dual Axis (IDA) waveguide architecture (Figure 1) which multiplexes beam expansion
and extraction gratings using a high index modulation holographic LC-photopolymer material system optimized for wide
angle multiplex grating applications. Complementing this compact waveguide design, DigiLens’s Waveguide Integrated
Laser Display (WILD) projector provides a compact image generator combining despeckling, homogenization, beam
shaping, beam splitting and image projection from a Liquid Crystal on Silicon (LCoS) panel.

Figure 1: DigiLens IDA waveguide architecture.

Optical Architectures for Displays and Sensing in Augmented, Virtual, and Mixed Reality (AR, VR, MR),
edited by Bernard C. Kress, Christophe Peroz, Proc. of SPIE Vol. 11310, 113100I
© 2020 SPIE · CCC code: 0277-786X/20/$21 · doi: 10.1117/12.2551872

Proc. of SPIE Vol. 11310 113100I-1

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 2. DIGILENS WAVEGUIDE TECHNOLOGY
2.1 Switchable Bragg Gratings
DigiLens’s Switchable Bragg Grating (SBG) waveguides2 enable switchable, tunable and digitally reconfigurable color
waveguide displays with a field of view, brightness and form factor surpassing those of competing technologies.
DigiLens waveguide gratings are printed into a thin layer of a proprietary monomer and liquid crystal (LC) mixture that
can provide any required combination of diffraction efficiency and angular bandwidth in a thin waveguide with high
transparency and very low haze and can be laminated to integrate multiple optical functions. SBGs have several
fundamental advantages over our nearest rival: Surface Relief Gratings (SRGs) 3, as used in the Microsoft HoloLens,
including higher efficiency and brightness, better uniformity and electrical switching capability. SRGs suffer from higher
diffraction orders and dispersion.

Figure 2: Conventional waveguide architecture.

Figure 2 summarizes the basic theory underlying SBGs based on Kogelnik’s coupled wave theory for thick holographic
gratings4 and the correction for a birefringent medium by Montemezzani and Zgonik5. A fundamental difference
between birefringent (anisotropic index) gratings and isotropic index gratings is that, in the former, the wave propagation
vectors and energy propagation vectors are at different angles. Figure 2a shows a basic transmission Bragg grating with
a grating vector K and Bragg fringe separation Λ and surface grating pitch Λy, where ki, kd are the incident and diffracted
wave vectors, and si, sd are the incident and diffracted energy propagation vectors (or Poynting vectors), which are
inclined at angles α1,α2 to the propagation axis (z). The walk-off angles between the wave vectors and the energy
propagation vectors, represented by the angles δ1, δ2, result in a shift of the diffractive efficiency versus angle
characteristics relative to the Kogelnik prediction. The incident and diffracted polarization unit vectors e1, e2, may have
any direction. Equations for calculating the diffraction efficiency for an unslanted grating are shown in Figure 2b.
Application of the equations for calculating diffraction efficiency requires transformation of vectors into the reference
frame of the slanted grating, which can be accomplished using Euler angle transformations. The equations are similar to
Kogelnik’s equations, apart from the parameter ξ, governing coupling between the incident and diffracted beams, which
is now expressed in terms of the polarization vectors and the relativity permittivity modulation tensor εr, which is
illustrated for the isotropic modulation case in Figure 2c. The parameter ν, governing detuning from the on-Bragg
condition (Figure 2d), is expressed in terms of the wavevector mismatch Δk arising in the off-Bragg condition
(illustrated in Figure 2e). In birefringent gratings, the index and modulation can be represented by the equivalent uniaxial
crystal corresponding to the grating. The refractive index tensor for the equivalent optical crystal with optical axis
aligned parallel to the grating vector is shown in Figure 2f, and the crystal ordinary and extraordinary refractive indices
(no,ne) are shown Figure 2g.

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 2.2 Traditional dual axis expansion waveguide architectures
DigiLens waveguides can be configured using dual axis expansion architectures comprising an input grating, a fold exit
pupil expander grating, and an output grating color waveguide (Figure 3). Color implementations can have two air-
separated waveguide layers comprising one monochromatic waveguide and a second waveguide shared by the two other
primary colors or, alternatively, three waveguide layers: one for each of red, green and blue. In many applications, each
waveguide contains a single grating layer addressing the entire field of view, the grating layer being sandwiched by a
pair of high index substrates to form a waveguide. The output and fold gratings are normally passive while the input
gratings can be switched to eliminate color crosstalk. Fold gratings, which typically have fringes clocked at 45° to the
input guided beam, deflect the beam path through 90° in the plane of the waveguide and provide horizontal beam
expansion with the output grating providing vertical beam expansion. Fold gratings enable two-dimensional beam
expansion in a single waveguide layer, which translates into lower cost, reduced haze, and improved brightness. The
gratings, particularly the input gratings, can have rolled K-vectors (that is, a continuously varying Bragg fringe slant
angle along the waveguide) with the surface period of the grating being held constant and matched to the periods of the
other gratings to eliminate color dispersion. Since the Bragg diffraction efficiency profile changes as a function of the
slant angle, rolling the K-vectors of the grating expands the effective angular bandwidth of the waveguide.

Figure 3: Conventional dual axis expansion waveguide architecture.

A waveguide architecture of the type shown in Figure 3 is used in the DigiLens Crystal25 two-layer monocular
waveguide display (formally known as the DigiLens MonoHUD). One major application is a fully eyes-on-road
motorcycle HUD for providing critical road information to the rider safely, efficiently and without interfering with the
helmet visor. The display provides a maximum brightness of 5,000 nits, nHD (640×360) image resolution, an
unobscured user FoV of 105º, an AR display FoV of 25º diagonal and can accommodate prescription. The DigiLens
Crystal25 will be supplied in volume by Young Optics of Taiwan.

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 2.3 DigiLens IDA Architecture
An IDA waveguide combines the functions of the fold and output gratings to provide simultaneous vertical and
horizontal expansion and beam extraction while reducing the grating real estate. As shown in Figure 4, the beam
expansion and extraction are accomplished using a pair of crossed fold gratings (referred to as Multiplexed Grating 1 and
Multiplexed Grating 2 in Figure 4). A leftward propagating portion of the FoV injected into the waveguide by the input
grating is folded and expanded horizontally by Multiplexed Grating 1 while Multiplexed Grating 2 expands the beam
vertically and extracts it from the waveguide to the eyebox. The rightward propagating portion of the FoV is handled in a
similar fashion with Multiplexed Grating 2 now folding and expanding the beam horizontally and Multiplexed Grating 1
expanding the beam vertically and extracting it to the eyebox.

Figure 4: Principle of the DigiLens IDA waveguide.

Figure 5 shows wave number space (k-space) representations of conventional dual axis expansion and integrated
dual axis waveguides in. The grating vectors (K-vectors) are illustrated by the arrow lines in each case. The outer
circle in each diagram corresponds to the maximum waveguide angle and the inner circle to the TIR limit of the
waveguide. The waveguide angular carrying capacity is represented by the space between the two concentric rings.
Typically, in wide angle IDA waveguides, the K-vectors are arranged asymmetrically.

Figure 5: Examples of k-space diagrams for traditional and IDA waveguide architectures.

A further benefit of IDA architectures is the reduced average holographic photopolymer refractive index requirement.
For example, using traditional dual axis expansion, an index of 1.76 is required to achieve a 50º FoV; an equivalent IDA
architecture requires an index of only 1.57 due to the need to support only half the FoV. Using k-space mapping it can
be shown that a FoV of around 100º diagonal is achievable using a photopolymer with an average index of 1.62.

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 Figures 6-8 illustrate how monochromatic (i.e. red, green or blue) information can be projected over a FoV by
propagating the left and right portions of the FoV through the IDA grating. Figure 6 shows the k-space diagrams for
each FoV portion and for the full FoV. Figure 7 illustrates the principle light paths and corresponding grating footprints.
Figure 8 provides a plan view of the input and multiplexed grating showing the fold only area, the multiplex area for
each of the two multiplexed gratings and the prescription multiplex area.

Figure 6: Representation of a monochromatic IDA waveguide using k-space diagrams.

Figure 7: Plan view of principal IDA light paths and grating footprints.

Figure 8: IDA grating configuration plan view.

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 As shown in Figure 9, two (or more) waveguides can be used per color to support a wide FoV. The second
waveguide can have gratings whose K-vectors are mirror images of those in the first waveguide. In many
applications the multiplexed gratings can have asymmetric K-vectors.

Figure 9: Two waveguide IDA configuration.

Figure 10 illustrates the more compact optical layout achievable with an IDA waveguide in comparison with a dual axis
expansion waveguide of equivalent specification.

Figure 10: Comparison of traditional dual axis and integrated dual axis optical layouts.

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 DigiLens’s Iris color headset provides the platform for the company’s first IDA waveguide display (Figures 11-12). Iris
uses the DigiLens Crystal50 Mixed Reality waveguide (Figure 13) and is available with 40º or 50º FoV 720p resolution
picoprojector options. The display is focused to infinity and has a transparency of 92%. The Iris headset has a button-
activated pop-up visor which is out of the user’s line of sight when not in use. An elasticated foam headband snugly
secures the display the user’s head. A fast Visual Simultaneous Localization and Map-building (VSLAM) head tracker
collects 6 degree-of-freedom head positional data. Plug and play USB and HDMI inputs ensure broad compatibility with
any laptop or smartphone. The specification of the DigiLens Iris color headset is provided in Table 1.

Figure 11: DigiLens Iris using Crystal50 IDA waveguide architectures.

Figure 12: DigiLens Iris using Crystal50 IDA waveguide architectures front and side elevation views.

Figure 13: DigiLens Crytstal50 Mixed Reality waveguide.

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 Table 1: DigiLens Iris color headset specification.

Parameter Specification
Field of View 50º diagonal binocular or 60º diagonal binocular
Transparency 85% (estimated)
Resolution HD 720p (16:9)
Eye relief 17mm
Eyebox 12mm x 10mm
Focus distance Infinity
Color RGB
Weight 280 grams
Interface HDMI, USB
Tracking VSLAM 6DoF; Refresh rate: up to 200fps; Latency: < 6ms
RGB Camera FoV: 86º ; Still image: 3872 x 2592; Video: 30fps, 1920x1080

A binocular overlap of the left and right waveguide eyeglass display can be used to provide binocular FoVs of either 50º
or 60º total binocular FoV (Figure 14). The resolution and FoV are limited only by the picoprojector. DigiLens is
working with leading picoprojector manufacturers to scale the optical architecture to 90º near term and, eventually, up to
150º as OEM application demand materializes and higher resolution picoprojector solutions emerge. Delivering
resolution improvements commensurate with such large FoVs is a major challenge for next generation AR displays.

Figure 14: DigiLens Iris using Crystal50 IDA FoV configurations.

Figure 15 shows a waveguide design in which two 50° diagonal waveguides, each targeting half of the FoV in a
monocular arrangement, are aligned to yield a 70° horizontal x 35° vertical FoV. Each waveguide set can be
overlapped by 50° horizontally to achieve a 100° diagonal binocular FoV.

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 Figure 15: Wide FoV IDA waveguide configuration.

2.4 DigiLens Waveguide Integrated Laser Display (WILD)

The low etendue of laser emitters makes them the ideal choice for delivering excellent color gamut, high brightness and
compact form factors in AR displays. Lasers can be expected to replace LEDs as light sources in next generation
waveguides where the coherence and narrow spectral bandwidth of lasers is ideally matched to diffractive optics.
However, laser image generators suffer from speckle caused by the coherence of laser beams and, when introduced into
waveguides, produce other illumination nonuniformities, such as banding, resulting from the gaps or overlaps between
totally internally reflected collimated beams arising from imperfect beam collimation and/or waveguide substrate
defects. DigiLens’s Waveguide Integrated Laser Display (WILD), shown in Figure 16, combines the functions of input
coupling, illumination homogenization (including despeckling) beam splitting, light extraction for illuminating a
microdisplay panel, transmission of reflected image modulated light for projection and beam shaping to match the
angular variation of the projection lens aperture. All of these functions are integrated in a compact waveguide structure
with no moving parts and high light transmission efficiency.

Figure 16: The DigiLens WILD module.

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 RGB light from a compact laser module is coupled in the waveguide using an input coupler (which can be a SBG or a
prism). The input coupler also performs anamorphic beam-shaping and collimation. An active SBG despeckler array
in each waveguide layer averages (spatially and temporally) the guided beam wavefronts to reduce speckle. Stacked
RGB waveguide layers provide full color homogenization with the RGB output grating stack overlapping a microdisplay
panel. WILD can be used with LCoS or MEMs microdisplays. A beamsplitter layer working in tandem with each SBG
array performs further debanding and homogenization. The output gratings have light diffusing properties and use rolled
K-vectors to provide beam expansion across the microdisplay panel with a spatially varying diffusion cone matched to
the projection lens angular aperture. The output grating eliminates the need for a bulky and inefficient beamsplitter cube.

3. DIGILENS WAVEGUIDE MANUFACTURE

3.1 DigiLens holographic photopolymer
Key to the success of DigiLens’s waveguides is the company’s proprietary holographic material, called Reactive
Monomer Liquid Crystal Mix (RMLCM), specially developed for AR waveguides. The material combines industry
proven monomer and LC components. DigiLens’s holographic waveguides are based on the principle of holographic
phase separation. During laser exposure under an interference pattern formed by a master, the liquid crystal and
monomer components diffuse and self-arrange, with polymerization being initiated in the bright regions and the LC
diffusing to the dark regions to form Bragg gratings comprising alternating polymer-rich and LC-rich fringes6. SBGs
can be used as passive components where the large range of index modulation combined with high average grating and
substrate refractive indices greatly expand the scope of holographic gratings, enabling wide angular bandwidths and
multiplexed gratings. The gratings can be switched, if required, using an applied voltage to realign the optical axes of
the LC molecules within the LC to provide an effective refractive index that matches the polymer refractive index,
creating a transparent cell. Switching can be used to avoid color crosstalk in multilayer color waveguides. As shown in
Table 1, which compares current holographic photopolymer materials, RMLCM index modulation (for a typical grating
thickness of 2-micron), at 0.17, is around six times than that of conventional material. DigiLens has developed high
transparency uniform modulation formulations RMLCM which largely eliminate LC droplets, a principal contributor to
haze, which is well below 1% in DigiLens waveguides.

Table 1: Comparison of current holographic photopolymer materials.

Parameter Bayer (HX102) Polygrama (SM TR532) DigiLens (RMLCM)

Haze < 2% < 1% < 1%
Typical photopolymer thickness 16 ± 2 μm 8 ± 2 μm 2 ± 1 μm
3 3
Density 1.12 g/cm 1.17 g/cm ~1.1 g/cm3
Refractive index photopolymer 1.49 ~1.5 1.5-1.7
Refractive index modulation 0.02 0.03 ~0.15

3.2 DigiLens waveguide printing process

The manufacture of DigiLens waveguides is a printing process akin to photocopying, which offers a significant cost
advantage over the high-precision surface relief embossing process used to make SRGs. With consumer products in
mind, DigiLens has developed a process7 (Figure 17) based on contact copying from masters onto substrates spray-
coated with DigiLens RMLCM using DigiLens’ DL2500 precision inkjet printer. The process is fully scalable from
eyewear up to large scale HUD applications (e.g. automobile HUDs and architectural smart windows) and will
eventually be translated to plastic substrates. In the longer term, DigiLens envisages a roll-to-roll process. DigiLens’s
process can handle any waveguide grating architecture and grating configuration simply by building the extra complexity
into the master hologram. In contrast, SRG processing gets progressively more challenging as optical complexity

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 increases. A further advantage of our process is that modulation and grating thickness, the key determinants of efficiency
and uniformity, can be controlled dynamically at the print head. Such dynamic modification of a grating is not possible
with conventional holographic or SRG processes where the role of index modulation is played by etch depth and each
variation of the grating would entail repeating the complex and expensive tooling process.

Figure 17: DigiLens waveguide manufacturing process.

Authoring of DigiLens waveguides is performed using custom-developed software tools specially developed for
modelling our birefringent gratings and currently only available to licensees. These include dynamic-link library (DLL)
code running under ZEMAX®, capable of ray tracing anisotropic grating waveguides, and a suite of other proprietary
tools for grating and waveguide system modelling for determining optimal grating prescriptions and footprints to meet
specific FoV requirements. The coated substrate is then exposed in a multi-station laser exposure rig effectively
recording the gratings into the RMLCM layer with 30-micron resolution and with full part repeatability. Once the non-
recurring master costs are met, the replication costs are relatively insignificant and part count, assembly time and touch
labor are greatly reduced, and part quality is much higher. Another feature of the DigiLens process, with major
implications for yield and quality, is the close integration of authoring and fabrication. Reverse ray tracing (from the
eyebox) using DigiLens’ software tools8 can identify which of the millions of ray-grating interactions in the waveguide
contribute to the image seen from the eyebox. This allows the identification of specific regions of a grating that require
index modulation or thickness adjustment to overcome nonuniformities in the waveguide output image.

4. SUMMARY
DigiLens is prototyping a novel Integrated Dual Axis (IDA) waveguide architecture which multiplexes beam expansion
and extraction gratings using a high index modulation holographic liquid crystal and photopolymer material system
optimized for wide angle multiplex grating applications. DigiLens IDA waveguides enable compact wide angle, full
color laser illuminated consumer AR waveguide that overcome wide field-of-view (FoV) color, daylight-compatible
brightness and ultra-compact form factors at an acceptable price. Complementing this compact waveguide design,
DigiLens’s Waveguide Integrated Laser Display (WILD) projector provides a compact image generator combining
despeckling, homogenization, beam shaping, beam splitting and image projection from a Liquid Crystal on Silicon
(LCoS) panel. DigiLens’s waveguides are manufactured using is a unique phase separation holographic photopolymer
used in a precision inkjet coating and holographic phase separation process that can deliver the high volumes and low
costs needed for consumer AR products.

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 REFERENCES

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Digest Tech. Papers 49(1), 204-207, (2018).
[3] Levola, T. and Laakkonen, P., “Replicated slanted gratings with a high refractive index material for in and
outcoupling of light,” Optics Express, Vol.15, No. 5, 2067-2074, (2007).
[4] H. Kogelnik, “Coupled wave theory for thick hologram gratings” Bell Labs |Technical Journal, 48-9,2909-2947,
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[5] G Montemezzani, M. Zgonik, “Light diffraction at mixed phase and absorption gratings in anisotropic media for
arbitrary geometries”, Physical Review E 55 (1), 1035-1047, 1997.
[6] Liu, Y.J. and Sun, X.W., “Holographic Polymer-Dispersed Liquid Crystals: Materials, Formation, and
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[7] Waldern, J.D., Morad, R. and Popovich, M.M., "Waveguide Manufacturing for AR Displays, Past, Present and
Future," OSA Technical Digest, FW5A.1, (2018).
[8] Waldern, J.D., Grant, A.J. and Popovich, M.M., “Waveguide optics enabled consumer HUDs revolutionizing
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