The Best XR Headsets for Training in 2025
Industry leaders like Walmart and Emirates Airlines are turning to augmented, mixed, and virtual reality to better training and onboard employees.
This isn’t surprising since XR training delivers results like:
Improved Effectiveness and Retention: VR training improves learning outcomes with a 76% increase in effectiveness compared to traditional methods. Employees retain up to 80% of knowledge even after a year. (Source: Takeaway Reality)
Increased Confidence and Cost-Effectiveness: 40% of VR learners saw an improvement in confidence compared to classroom learners, and a 35% improvement over e-learners in acting on what they learned. VR training is also the most cost-effective when implemented at scale. (Source: PwC Study)
Stronger Retention and Confidence Boost: Immersive learning through XR boosts retention by 75% and learner confidence by 275%, making it a game-changer for industries. (Source: Unity)
IF you do it right. Does this mean ALL training should be done in XR? Nope.
If your organization has low frequency, high risk activities, XR training is a great fit.
Why? XR triggers physiological responses (think: increased heart rate, increased breathing rate, etc.) from users. A well-designed XR experience feels closer to real life than a PowerPoint or 2D video game-like simulation, delivering more impactful results.
Aerospace, defense, and manufacturing have turned to XR for training, and choosing the right headset becomes crucial. Here's the catch: headsets in 2025 present a trade-off between computational power and mobility/form factor for comfort. Balancing processing power and comfort is key to maximizing the benefits of XR training.
Dauntless XR offers cross-platform apps and we work with customers all the time to select a headset that works for them. When we kick off an evaluation, here’s the criteria we look at:
Immersion Quality: The visual and auditory fidelity of the headset impacts a user's interest and comfort in the experience. High-resolution displays and realistic soundscapes create a more engaging training environment with real-world nuances. Depending on the data needed to be visualized however, the compute power required to deliver realistic immersion may not be necessary.
Onboarding Time: A user-friendly interface and intuitive controls, mean a shorter setup, allowing trainees to focus on the content rather than the technology itself. Some headsets have a harder adoption period than others. To evaluate this we understand the technical readiness of the end user and determine their tolerance for a steep or gentle learning curve. The experience won’t be useful in the long term if the hardware is too cumbersome to get started.
User Environment: Headsets need to be versatile enough to cater to different training needs across various sectors. Here we look at where the training will take place and how variable the environment is. Selecting an appropriately flexible headset ensures that IT can integrate the technology across different departmental training programs.
Technological Robustness: Durability and reliability are vital, especially in demanding environments. A robust headset will withstand the rigors of frequent use and provide consistent performance over time.
Price: Affordability is a key consideration, and budget drives most organizations purchasing choices. The cost of the headset should align with the value it provides in enhancing training outcomes.
Mobility: Headsets can be tethered to a computer or battery pack or standalone and untethered. Are trainees sitting, standing, or moving around? How mobile your users need to be will determine which device type is best.
Situational Awareness: Headsets can be see-through (transparent visors), pass through, or fully immersive. How aware of their surroundings and other trainees or instructors will determine the level of situational awareness is necessary.
Applying the above criteria, here are the top headsets we recommend in 2025 for companies upleveling their training programs.
Meta Quest 3
Meta Quest 3 is the most popular in the XR landscape for a reason. With its solid optics and spatial audio, it provides an immersive experience in a mobile package. The device is wireless, and trainees can move freely without being tethered to a computer. The Quest is ideal for sectors like retail and manufacturing where mobility and situational awareness is key.
Advantages:
Mobility: The wireless design makes the Quest 3 a good choice for training use cases where the user needs freedom of movement.
User-friendly interface: We see a low device onboarding time with this headset, making it a good entry point for XR for users unfamiliar with the platform.
Affordability: The Meta Quest 3 is budget-friendly, making it a great choice for organizations looking to deploy training solutions at scale with a limited budget.
Limitations:
Enterprise Support: Meta’s enterprise solutions are less robust compared to HTC’s, which is a drawback for large-scale deployments. Devices are tightly coupled with a Meta account. Use in a professional setting likely requires the license of a third party device management platform, and that additional cost counters the budget friendly price point of the device.
Build Quality: While durable, it’s not as rugged as the other options on this list, which is a consideration for industrial environments.
Less Mixed Reality Focus: Although the Meta Quest 3 has pass through, it does not excel in this area as much as devices like the Varjo XR-4 or the RealWear Navigator 520. This makes the headset a poor choice for scenarios that require situational awareness.
HTC VIVE Focus 3
The HTC VIVE Focus 3 is an enterprise-grade headset designed for professional and industrial use cases. Unlike the Meta Quest 3, HTC designed the VIVE Focus 3 for businesses, and includes enterprise-level device management tools, secure data handling, and IT integration support. Its rugged magnesium alloy frame provides durability in demanding environments like manufacturing, aerospace, and defense, while its swappable battery system minimizes downtime during extended training sessions. The VIVE Focus 3 is well equipped to handle scalable deployments and enterprise applications, catering to organizations that prioritize performance, durability, and advanced hardware capabilities
Advantages:
High-Resolution Display: It offers a superior 5K resolution and a wide 120-degree field of view, providing incredibly detailed visuals—ideal for training simulations requiring precision.
Swappable Battery: The swappable battery design ensures minimal downtime during long training sessions.
Enterprise Features: HTC provides extensive enterprise support, including device management tools and secure data handling, making it a strong choice for businesses prioritizing IT integration and scalability.
Enterprise-Grade Design: Built with a robust magnesium alloy frame, the Vive Focus 3 is designed for heavy usage in professional settings like manufacturing or aerospace training.
Limitations:
High Price Point: The VIVE Focus 3 is priced on the higher end compared to other standalone headsets like the Meta Quest 3. This may make it less accessible for smaller organizations or those working with tight budgets, especially for large-scale deployments.
Heavier Build: While the VIVE Focus 3 is ergonomically designed, its heavier weight (compared to lighter headsets like the Meta Quest 3) can make it less comfortable for users during long training sessions, particularly for employees not accustomed to wearing headsets for extended periods.
Standalone Performance Limitations: Though it’s a powerful standalone headset, the VIVE Focus 3 is not as capable as tethered headsets like the Varjo XR-4 when it comes to processing extremely high-fidelity simulations or graphics-intensive training applications. For complex training scenarios, the standalone nature can be a bottleneck.
Less Mixed Reality Focus: Although the VIVE Focus 3 supports some mixed reality features, it does not excel in this area as much as devices like the Varjo XR-4 or the RealWear Navigator 520. This is a limitation for scenarios that require situational awareness.
Controller Ergonomics: The controllers, while functional, are not as ergonomic or intuitive as some competitors, which could cause minor usability challenges in training scenarios that require precise interactions.
Varjo XR-4
Choose the Varjo XR-4 if your training use case demands unparalleled visual detail, precise analytics (like eye tracking), robust mixed reality capabilities. We will caution you that your business needs the budget and infrastructure to support it. With its ultra-high-resolution display, it's particularly suited for detailed training in fields like aviation and medicine, where clarity and accuracy are paramount.
Advantages:
Unmatched Visual Fidelity: The XR-4 boasts human-eye resolution (over 70 PPD), making it the best option for training scenarios that require extreme visual detail, such as medical simulations, aerospace operations, and design reviews.
Mixed Reality Excellence: With advanced mixed reality capabilities, the XR-4 allows for seamless blending of real and virtual environments, perfect for hands-on training where physical and digital interactions are crucial.
Eye Tracking & Analytics: The built-in eye tracking provides precise user insights, enabling trainers to measure attention, focus, and performance during training sessions.
Enterprise-Grade Build: The XR-4 is designed for professional use, with robust hardware and support for enterprise-level integrations.
Compatibility with High-End Platforms: It supports demanding software and workflows, making it ideal for industries like aerospace and defense, where precision and performance are non-negotiable.
Wide Field of View: Its 115-degree field of view enhances immersion, ensuring trainees feel fully engaged in the virtual environment.
Limitations:
High Cost: The Varjo XR-4 is one of the most expensive headsets on the market.
Hardware Requirements: It requires a powerful PC setup to operate, which adds to the overall cost and complexity of deployment.
Limited Portability: Unlike standalone headsets like the Meta Quest 3 or Vive Focus 3, the XR-4 relies on tethering to a PC, which can limit mobility in certain training scenarios.
Steep Learning Curve: The advanced features and setup might require more technical expertise to implement effectively, which could be a barrier for teams without dedicated IT support.
RealWear Navigator 520
RealWear Navigator 520 is built for extreme and hazardous environments. Its ruggedized design is tailored for hands-free operation, making it ideal for industries like construction and field services where users need to access data while keeping their hands free. In our opinion, Realwear is best for on-the-job training or see-what-I-see training scenarios.
Advantages:
Hands-Free Operation: The RealWear 520 is designed for hands-free use, making it ideal for training scenarios in environments like manufacturing, construction, and field operations.
Durability: Built to withstand harsh environments, it’s rugged, water-resistant, and dustproof, making it perfect for industries like aerospace and defense where durability is essential.
Voice-Controlled Interface: The headset features 100% voice control, allowing users to navigate and interact with training content even in noisy environments.
Lightweight and Comfortable: Weighing just 0.6 lbs, it’s comfortable for extended wear during long training sessions.
Integration with Workflow Tools: It supports a wide range of enterprise applications and integrates seamlessly with tools like Microsoft Teams, making it a great choice for collaborative training.
High-Resolution Camera: Equipped with a 48MP camera, it enables high-quality video capture and real-time sharing for remote training or expert guidance.
Battery Life: The swappable battery design ensures minimal downtime during training sessions, with up to 8 hours of continuous use.
Limitations:
Limited Immersion: Unlike fully immersive VR headsets, the RealWear 520 is an augmented reality (AR) device, so it’s less suitable for training scenarios requiring deep immersion or complex simulations.
Smaller Display: Its micro-display, while effective for instructions and workflows, may not be ideal for training scenarios that require large, detailed visuals.
Niche Use Cases: Best suited for task-based training rather than soft skills or high-fidelity simulations.
Enterprise-Focused: It’s tailored for operational environments, which may limit its appeal for organizations looking for broader training versatility.
Now that you have the hardware you can move on to choosing the right software, which we cover here in another blog.
