This project aimed to reduce user discomfort caused by the weight and heat of all-in-one VR headsets, which house the computing system directly on the device. By exploring materials, weight-distribution structures, and heat-dissipation solutions, the design enhances comfort while maintaining performance. I led insight-gathering and problem definition, developed concepts, and conducted ergonomic studies with prototypes. The final concept was presented to internal engineering teams and the CTO to guide further development.