Assisted reality (aR) hands free head wearables for manufacturing

Enable line workers with secure hands-free collaboration


Digital workspaces are transforming how organizations think about operational efficiency and productivity. When it comes to manufacturing, digital transformations must also enhance safety around machinery or in dangerous working environments. That’s why augmented reality or assisted reality in manufacturing has been slow to take hold — until now.

RealWear’s assisted reality (aR) solutions are leading manufacturing’s digital transformation with hands-free voice-controlled industrial wearables, designed around safety.

Hands-free solutions for smart factories

Smart factories aim to reduce inefficiencies and ramp up production to meet growing global demand. Digital transformation through IoT, AI and connected workers will enhance your workforce’s efficiency to deliver tangible return-on-investment.

But this doesn’t change the inherent dangers of working around machinery. A digitally transformed manufacturing factory floor is still bustling with loud and distracting activity with a looming danger of serious injuries. Workers need to be able to navigate these environments safely while doing their job.

Efficiency and safety are not mutually exclusive. RealWear devices empower workers by helping them get the information they need at the right time and in the right context.

With the power of a wireless Android tablet in the form of smart glasses, workers can access and view equipment manuals, multimedia files, complete documents and collaborate with experts in real-time with video calls. And because our assisted reality devices are entirely hands-free, manufacturing workers can continue to work with their hands and view information without distraction.

Key benefits of hands-free controls

RealWear assisted reality headsets are voice-activated to:

  • Help workers focus on their immediate surrounding
  • Enable faster access to and reference of resource materials
  • Allow the use of both hands
  • Work even when wearing heavy-duty protective gloves
  • Reduce risk of dropping other tools and equipment

Digital transformation in manufacturing with aR

SLA fulfilment


Low situational awareness results in slow response. Technicians have difficulty meeting aftermarket SLA’s with a geographically distributed customer base, which triggers costly penalties.


Our solution

Turn the customer into your field diagnostic team by calling with video instead of a voice call. Technicians improve efficiency and accuracy by using the voice-activated RealWear device with remote mentor solutions to: connect hands free with Product Quality Engineers (PQEs), capture images and videos, playback training videos, refer to manuals and more.



When production stops due to machine failure, on-site technicians need immediate assistance to resume production. However, the expert for this machine may be located in a different city, state, or country.

Our solution

Through peer-to-peer video collaboration on our assisted reality device,  experts can provide assistance by telestrating remotely to pin-point the exact issue – even in high-noise environments. Hands-free communication permits technicians hassle-free use of tools to operate machines.

Secure docs


Workers do not have the latest knowledge for manufacturing operations, including machine installation, inspection and maintenance procedures. Paper copies are kept in binders adjacent to the manufacturing lines for reference by operators, but these are cumbersome and pose a security risk.

Our solution

Document navigator and single sign-on (SSO) allows documents to be securely synced to RealWear devices. Operators simply scan a QR code on a machine and are brought directly to the correct document to address their issue. Files are then remotely wiped when security credentials are revoked.

5 benefits of RealWear assisted reality in manufacturing

Supports safety requirements

RealWear headsets are designed with safety in mind — in all industrial environments. They’re ruggedized,  durable and compatible with PPE including hard hats, eyewear, masks and even hazmat suits. The micro-displays are slim to maintain field of vision but are also adjustable to be moved out of the wearer’s view.

Improves information access

AR in manufacturing helps workers access the information they need safely and efficiently to improve the installation, monitoring, maintenance and repair processes. While it’s possible to get the same access on other devices like laptops, tablets and smartphones, they are cumbersome, often require two hands and can be easily dropped.

Assisted reality technology displays digital content in the worker’s line of sight without inhibiting their vision or taking their hands or attention off the task in front of them.

Supports safety requirements

RealWear headsets are designed with safety in mind — in all industrial environments. They’re ruggedized,  durable and compatible with PPE including hard hats, eyewear, masks and even hazmat suits. The micro-displays are slim to maintain field of vision but are also adjustable to be moved out of the wearer’s view.

Increases accessibility to experts and mentors

RealWear headsets’ high-resolution camera, wireless connectivity, noise-canceling microphones, and integrated audio enable manufacturing workers to remotely collaborate with offsite experts or mentors in real-time. With seamless out-of-the-box integrations with collaboration applications (e.g. Microsoft Teams, Zoom, Librestream), the remote mentor can visually present information on the headsets’ micro-display.

Boosts productivity and efficiency

Having instant access to resources or information allows workers to be more knowledgeable about their job. Workers are able to access relevant information at the point of need and in the right context.

Reduces operational costs

RealWear headsets enable offsite supervisors and experts to remotely view the site from the onsite workers’ perspective. For organizations with locations all over the world, this eliminates the need for costly international travel of multiple stakeholders.

This can greatly improve first-time resolution times, increase first-time fix rates or faster completion of site acceptance testing. This means reducing downtime and being productive and efficient.

High-impact benefits

  • IP66 rated/drop proof /dust proof
  • Explosion proof (intrinsically safe model only)
  • 8-10 hours battery life (not swappable for HMT-1 only)
  • Install virtually any Android application
  • Large ecosystem of remote mentor applications
  • Drive process compliance and quality
  • Lower time to access information
  • Use hands-free while wearing gloves
  • Workaround to travel restrictions
  • Maintain situational awareness
  • Bring knowledge to operator at the moment of need

Faceoff by Harley Davidson: iPhone vs. RealWear HMT-1

Communicating in a manufacturing plant can be challenging. Watch, as Team RealWear visits a Harley dealership for a face-off between an iPhone and RealWear’s head-mounted Android device, testing noise cancellation while remotely collaborating and running a ten-point inspection of a Harley bike.

HMT-1 connected worker in steel plants

Watch specialists from Washington based Seaport Steel use the RealWear HMT-1 to aid work in steel cutting, inspections, and machine maintenance and troubleshooting. The Messer Group’s solution, compatible with the RealWear device and other wearable technology or smart glasses, allows a user to navigate their device with voice commands to speed up digital workflow in field maintenance.

Solution specific RealWear accessories

Success stories

Honeywell transforms disruptions into opportunities with RealWear

The COVID-19 social distancing guidelines prevented the Honeywell Process Solutions team from performing onsite validations and testing of its customers’ newly implemented industrial equipment.


Nemco pioneers a new way of working for the food industry with deployment of RealWear assisted reality wearables

Leading solution provider for the Nordics food industry uses RealWear’s Industrial Strength Assisted Reality voice-controlled wearable devices to keep wide-ranging food supplies safe for the Nordics, and passes on a ten-fold fee reduction to customers in certain scenarios. 

STIM reels in big savings with deployment of RealWear assisted reality head-mounted displays

The voice-activated wearable computers are keeping fish healthy by streamlining STIM’s entire inspections process through remote collaboration, whilst avoiding significant travel.

Enhanced video stabilisation enables RealWear to take assisted reality wearables for industry to the next level

With enhanced video stabilisation, users now benefit from improved cloud dictation, Dutch language support and Android 10 via over-the-air firmware update for RealWear devices.

RealWear’s Assisted Reality Wearable Solution Experiences Strong Momentum with Frontline Workers

Pandemic drives demand for virtual, remote industrial collaboration services in key industry segments, including Energy, Manufacturing, Food & Beverage, Automotive and Telecommunications.

Mace constructs a smarter way to work with RealWear wearables during pandemic

Enabling a reduction of travel by 75% with RealWear device running Microsoft Teams by its facade team, the construction leader plans to deploy more than 150 devices over the next few months.

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