Support arm thermal structure for extended reality glasses

A method of assembling a head-worn device, comprising:

• inserting a projector into a metal support arm, the projector comprising at least a rear surface, a front surface, a bottom surface, a top surface, a left surface, and a right surface, such that the metal support arm forms metal surfaces in contact with at least a portion of each of at least three of the surfaces of the projector to thermally couple to the projector to act as a heatsink;
• structurally attaching the metal support arm to an optical element holder of the head-worn device located in front of the projector;
• and
• structurally attaching the metal support arm to a rear structural element of the head-worn device,
• such that the metal support arm forms a structural support joining the optical element holder to the rear structural element without placing mechanical load on the projector.

A head-worn device, comprising:

• an optical element comprising an input optical element;
• an optical element holder configured to hold the optical element;
• a projector comprising at least a rear surface, a front surface, a bottom surface, a top surface, a left surface, and a right surface;
• a rear structural element;
• and
• a support arm assembly, comprising:
• a metal support arm:
• forming metal surfaces in contact with at least a portion of each of at least three of the surfaces of the projector;
• thermally coupled to the projector to act as a heatsink;
• configured to structurally attach to the rear structural element;
• and
• configured to structurally attach to the optical element holder, the optical element holder being located in front of the projector, such that the metal support arm forms a structural support joining the optical element holder to the rear structural element without placing mechanical load on the projector.