Slimterface, Flipterface & Customface for Bigscreen Beyond

The "Slimterface" is a DIY facial interface for the Bigscreen Beyond VR headset, created by Sporky on the Bigscreen Beyond discord, later modified by Val to be more universal and give more FOV

this project has taken me a lot of time and effort, so I would greatly appreciate if you could help me to create more open source VR hardware projects

you can do so by subscribing to my Patreon, Thank you for your attention.

here is why you would want to make your own:

• more area to more easily spread out the pressure
• lower eye relief for maximum FOV and better clarity
• nose gap to allow some air circulation, no more foggy lens, sweaty interface and itchy eyes.
• no pressure on the nose/nose bridge
• no pressure in the eye sockets
• optional top strap mounting, better compatibility with DAS/Index strap and other solutions
• lighter than BSB's custom fit interface at only 18g!
• no specially 3d printing material needed
• optional flip up version available!
• optional custom fitting available!
• open and customizable! feel free to remix it to fit your needs :)

recommended print settings:

• PLA or PETG
• 2perimeters
• 2 to 3 bottom/top layers
• 0.2 to 0.25 layer height
• 30 to 50% infill
• cura tree support if using cura 
• no brim/raft needed for adhesion

materials:

• 6x 3x2mm cylinder magnets
• self-adhesive 6mm or ¼" thick neoprene foam
• superglue

tools:

• utility knife with a brand new very sharp blade
• a marker
• a bit of 120/180 grit sandpaper 
• 3mm drill bit/reamer
• a screwdriver with a wide flat tip, such as Torx/Allen/Robertson 

Slimterface build process: 

1. Print BSB Slimterface with or without top strap depending on your needs.
    
2. print BSB Slimterface Foam template
    
3. remove supports on the Slimterface
    
4. ream the holes on the slimterface for the magnets with the drill bit
    
5. -ensure the right polarity by sticking a magnet to the tip of a screw driver and checking if it's repelled from the BSB's magnets, or attracted to the BSB interface's magnets.
   
   -if so do not move the magnet from the tip of the screw driver, put a drop of superglue in a magnet hole, and push the magnet in the hole of the Slimterface with the screw driver.
   
   -repeat for every magnets.
    
6. cut a 10x20cm rectangle out of neoprene foam
7. use the sandpaper on the wax paper covering the sticky side of the foam so the sharpie can draw on it
    
8. lay the Foam template on top of the neoprene foam on the wax paper side, and trace around the shape of the template with the marker
    
9. cut the neoprene foam with the utility knife on the inside of the marker line, flaring the cut outward by 30 to 45 degrees
    
10. peal the wax paper off of the Foam and stick it to the inside of the Slimterface, to facilitate alignment start with the corners of the cutouts for the connectors, and align with the outer edge all around the interface 
     
11. we're almost done! install the Slimterface onto your BSB and give it a try!
    -does it fit good? great! we're done then, enjoy!
    
    -is it too close to the lenses? double up the foam thickness! 
    
    -uneven pressure? cut away a bit of the foam thickness where there is too much pressure (bite-mod style!), repeat until it fit well.

Flipterface:

1. print Flipterface & Flipterface Hinge
    
2. cut away the print-in-place support on Flipterface
    
3. make sure the locking cams are well formed on Flipterface as this will impact how much force the flip up need
    
4. follow the same steps as for Slimterface for the foam and magnets
   /!\ The magnets are still needed for Flipterface for stability /!\
    
5. ream the hinge holes on both parts with a 2mm drill bit
    
6. press-fit a 2mm by 15mm(if you want it flush) or 20mm(it you want to be able to take it out easily later) metal pin through the hinges on each sides
    
7. Install the Bigscreen Beyond in the Flipterface: 
   -hook the headset on the hinge
   -hook the strap on the interface
   -leave more slack in the cable to not strain it while flipping it up

Customface:

1. 3D scan your face!
   -on windows with a Kinect V2
   -on iPhone (I don't have a iPhone so I can't tell you how, I just know it's possible)
    
2. follow the “custom interface process.txt” to create your custom model
   (there will probably be video documentation at some point, but not right now)
    
3. print the part(s) like for Slim/Flipterface
    
4. follow the same steps as for Slimterface for the magnets
    
5. for the foam, stick it down on the interface before cutting out the contour.
   you can also use thinner foam (or cut the foam in half by it's thickness with this tool) to get your eyes closer to the lenses in case where this can't be achieved otherwise, that is if you have entered the corresponding foam thickness value while creating the custom interface.

updates:

• 1.0 -initial release
• 1.1  -added 1 to 5mm spacers, to print with support and glue/tape in between Slimterface          and it's foam.
        -added custom spacer blank
• 1.2 -removed spacers and custom blank, 
        -edited step 11 to make it simpler
• 1.3 -added Flipterface 
        -added Custom fitted Slim/Flipterface.blend
        -added “custom interface process.txt”
        -added documentation for the latest additions 

you can contact me on Discord if you have any questions: @val.virtual