Augmented and virtual reality technology is reinvigorating industrial training. Over 70% of AR/VR revenue now comes from enterprise applications, with manufacturing and industrial sectors leading adoption (Innovate Energy Now, 2025). A recent survey found that 71% of manufacturing decision-makers have seen improved workforce safety and productivity from the adoption of AR/VR tech (XRA, 2024). Immersive environments are proven to boost knowledge retention and accelerate time-to-competency, making it a competitive advantage for high-stakes industries struggling with hiring and retention.

But with these benefits come new safety considerations. Unlike traditional desktop or mobile software, AR & VR applications rely on head-mounted devices that introduce risks: physical, ergonomic, and situational.

To help you navigate these challenges, we’ve outlined five essential safety features to look for when evaluating XR solutions for industrial applications. These recommendations are designed to keep your team safe, comfortable, and fully aware—no matter how immersive the experience.

Understanding the XR Landscape: VR, AR, MR, and XR

Let’s clarify the key terms:

Virtual Reality (VR): Fully immersive digital environments that block out the physical world.
Augmented Reality (AR): Digital information overlaid onto the real world, typically via see-through displays or mobile devices.
Mixed Reality (MR): Blends real and virtual worlds, allowing physical and digital objects to interact in real time.
Extended Reality (XR): The umbrella term for VR, AR, and MR.

Note: Safety features, and their criticality, vary depending on the level of immersion. For example, full VR may require more robust collision detection, while AR/MR headsets demand greater attention to real-world situational awareness. This guide focuses on safety best practices that are applicable across all levels of immersion. Read our blog for a more in-depth description of the different levels of immersion.

1. Realistic Hazard Alerts and Notifications

Augment, mixed, and virtual reality training is most effective when it mimics real-world hazards, such as equipment malfunctions or environmental dangers, and delivers real-time feedback to trainees. These can be visual cues, auditory signals, or even haptic feedback, all designed to help users react quickly to potential risks.

Make sure your software allows for customized content and configurable hazards. Tailor the training specific to the hazards your employees will face.

Tip: Opt for no-code platforms and/or providers that can create custom content. For an example of customizable mixed reality workflows, see the Katana XR platform.

2. Exit/Stop Features

Fully immersed virtual reality is a powerful tool, but it can be overwhelming, and induce “sim sickness” especially for new users. Every VR training system should offer an intuitive emergency stop feature that lets users instantly exit a scenario if they feel unsafe or disoriented. This feature is essential for preventing accidents or motion sickness, and it should be accessible whether the user is in VR, AR, or MR mode.

Tip: If you’re worried about sim sickness in new users, opt for an application that works in mixed reality.

3. Situational Awareness (Collision Detection)

When users are immersed in VR, it’s easy to lose track of their real-world surroundings. Without proper safeguards, this can lead to accidents like bumping into equipment, tripping, or walking into hazardous areas. Before selecting a headset and software, check that the device has forward facing cameras and sensing software to create a safe zone or boundary around the user. The application should issue warnings when a user approaches a real world obstacle or steps outside the designated area.

Tip: Opt for systems with “pass through” capabilities so users can see their real world environment without removing the headset if they are approaching an obstacle or trip hazard.

4. Ergonomics and Physical Comfort

Spending more than 15 minutes in a headset can be physically demanding if users aren’t properly kitted. Look for headsets that are easy to adjust with a supportive band or headstrap that runs over the top of a user's head. For the Meta Quest these are called the “Elite Straps”. This extra support take weight off the forehead and face and allow for longer immersive session time.

Tip: If headsets are communal and used by multiple trainees, look for headsets made easy to sanitize materials.

5. Headset Selection for Environment Safety

The right headset is crucial for safety, especially when moving from classroom training to on-the-job training or operational environments:

Classroom or Lab Training: Most headsets (VR, AR, or MR) are suitable, as the environment is controlled and risks are lower.
Operational/Field Use: Prioritize device with a see-through visor (true AR/MR) over pass-through VR. Pass through VR replicates the users field of view on a screen and has milliseconds of latency that don’t matter in a classroom, but could be life or death in the field. Instead look to lower-profile, ruggedized headsets like RealWear maximize situational awareness, minimize entanglement risks, and are built for tough environments. Make sure the displays are optimized for various lighting conditions.

Tip: For more on hardware selection, explore our XR Hardware Comparison Guide.

AR/VR is giving industrial training a much needed tech upgrade, but safety must always come first. By focusing on these five essential features training managers maximize both the impact and security of your spatial computing tech investment.

Ready to make safety your competitive advantage?
Contact Dauntless XR to learn how our expert team can help you deploy XR solutions that are safe, scalable, and tailored for industrial success.

5 Safety Features to Look for When Buying Industrial AR/VR Software