VIVE Facial Tracker Mount for Varjo Aero

Tested to work nicely on Varjo Aero headset. Don't use PLA as it will make the mounting fingers too fragile. Printed in vertical orientation with generous supports.

Update about XR-3: 
This occludes the LiDAR in the center and can leave a permanent impression on the headset. If you don't need the center camera and don't mind a bit of cosmetic damage, this works well with XR-3 too.

Here is my new recommended mount for XR-3:
https://nerdaxic.gumroad.com/l/varjo-compatible-htc-vive-facial-tracker-mount

Original instructions

Here is a face tracker mount for all Varjo headsets, tested by Varjo themselves and myself. Be sure to use a higher temp filament as the mount clips onto the exhaust ports of the headset, I would suggest using SLA if its available to you. The mount itself uses an m4 nut and is the same type as the default mount for the vive so you can use the screw from that if you want to. If the fit is a bit wobbly for you then I would suggest putting some felt behind the part that goes over the front of the headset.

UPDATE: Added a cable clip for the face tracker and inset the tension nut by 1.5mm which should now allow use of the original m4 bolt.

UPDATE: made the wire clip a little thicker on one side and removed a bit more material on the middle tab where the tracker goes hopefully preventing breakage.

Original model published January 09, 2022 in Thingiverse under CC BY 4.0