Additively manufactured metal frame

A head-mounted computing device comprising:

• a metal frame shaped as an eyeglasses frame, wherein:
• the metal frame is aluminum or titanium with a porosity between 0.1% and 2%;
• and
• the metal frame has a wall thickness between 0.15 mm and 0.75 mm;
• and
• one or more polycarbonate panels or glass windows, one or more displays, one or more sensors, a processor, and a power source mounted within the metal frame of the head-mounted computing device,
• wherein the head-mounted computing device has a weight between 75 g and 120 g.

A method of manufacturing, comprising:

• forming a metal frame of a head-mounted computing device shaped as a pair of eyeglasses, at least in part by:
• additively manufacturing the metal frame of the head-mounted computing device by performing laser sintering on aluminum powder or titanium powder, wherein:
• the metal frame is formed with one or more support structures integral with the metal frame;
• and
• the one or more support structures include one or more lattice support structures and/or one or more hairline support structures;
• mounting the metal frame on a jig using the support structures;
• cutting the one or more support structures off the metal frame;
• removing an outer surface of the metal frame via a mechanical reductive machining process;
• performing abrasive blasting on a remaining outer surface of the metal frame;
• and
• performing anodizing, painting, chromate conversion coating, or physical vapor deposition on the remaining outer surface of the metal frame;
• and
• mounting one or more polycarbonate panels or glass windows, one or more displays, one or more sensors, a processor, and a power source within the metal frame of the head-mounted computing device.