Extended reality headset assembly with pancake lens assemblies and method of assembling same

An extended reality (XR) headset assembly comprising:

• a headset adapted to be worn by a user and including:
• a support frame including a pair of opposing support arms extending along a longitudinal axis and spaced along a transverse axis perpendicular to the longitudinal axis;
• and
• a display system coupled to the support frame and including:
• an imaging equipment housing coupled to a forward portion of the support frame and positioned adjacent a forehead of the user;
• a pair of pancake lens assemblies extending from a bottom outer surface of the imaging equipment housing and spaced along the transverse axis including a left-eye pancake lens assembly positioned adjacent a left eye of the user and a right-eye pancake lens assembly positioned adjacent a right eye of the user, each pancake lens assembly is pivotably coupled to the support frame and includes a lens housing containing an image generator and an imaging lens assembly positioned between the image generator and the user's eye along an optical axis;
• and
• a controller housed within the imaging equipment housing and including one or more processors coupled to the pancake lens assemblies and programmed to display computer-generated images on the pancake lens assemblies.