RealWear has launched its latest assisted reality headset, Arc 3, alongside its new voice-controlled operating system, Ari OS.
The company announced the development on Tuesday 28 October 2025 in Vancouver, Washington, describing it as a major update for professionals working in manufacturing, logistics and healthcare.
According to RealWear, Arc 3 and Ari OS bring artificial intelligence (AI) and natural language capabilities directly to the frontline, allowing workers to access information hands-free in complex environments.
The Arc 3 weighs 179 grams and is designed for instant, intuitive use.
It is the first augmented reality (AR) headset to feature a see-through display with double retina resolution, delivering 40% more detail compared to other devices.
A dual-camera system provides high-quality imaging, while the lighter design supports all-day wear.
Workers can use voice commands to make calls, send messages, capture photos and adjust settings without using their hands.
The headset’s software, Ari OS, introduces natural language processing, enabling users to speak in full sentences rather than rely on preset prompts.
RealWear said the Arc 3 extends its current product line rather than replacing it, adding a more versatile option for everyday tasks.
Existing products such as the Navigator 520 will continue to serve rugged industrial sectors, while Arc 3 targets lighter environments.
The company noted that the device opens opportunities in sectors including logistics, warehousing and healthcare.
Fortune 100 companies already use RealWear technology in energy, automotive and manufacturing operations.
With Ari OS, RealWear said it aims to make hands-free, voice-first computing a practical standard across the industry.
The company plans to license Ari OS to other manufacturers to establish a unified software ecosystem for AR headsets.
Sebastian Beetschen, Chief Executive Officer of RealWear, said: “Having successfully served industries that require a heavy ruggedization headset, we are expanding the use case for our hardware and technology for new environments.
“We know there is demand for a new solution from industry such as manufacturing, robotics, clinical, pharma and healthcare environments. Arc 3 delivers on that.
“With the addition of Ari OS, we are democratizing access to a much wider pool of users beyond technical specialists to work more efficiently. It will be as seamless as talking to ChatGPT.”
RealWear said that since its founding in 2016, it has deployed tens of thousands of devices worldwide.
The company has built an ecosystem of developers and resell partners supporting enterprise outcomes across multiple industries.
Claus Eberhart, Vice President of Aftersales at BMW of North America, said: “This deployment has been pivotal in enhancing our service efficiency.
“By solving issues faster, we get customers back into their cars sooner, furthering our commitment to providing the best possible service experience.”
Dallas Olson, Vice President of Global Manufacturing and Engineering at Goodyear, said: “Microsoft Teams and RealWear have been the way we have been able to get almost all our projects done.
“That’s a dramatic shift for an organization.”
RealWear said Arc 3 will be available on a yearly subscription model.
The subscription includes free repairs or replacements, upgrades to the latest model and customer support.
Beetschen added: “We are offering a complete peace of mind to users with this new subscription-based model for Arc 3.”
Frontline personnel in manufacturing, automotive, logistics and healthcare environments rely on constant access to information while maintaining focus on physical tasks.
RealWear’s Arc 3 and Ari OS could improve workplace safety by reducing the need for handheld devices that can distract or obstruct workers.
The natural language voice system enables faster, more efficient task execution without interrupting protective equipment use.
These capabilities may assist industrial safety officers, plant engineers and maintenance managers responsible for compliance and operational efficiency in environments requiring strict PPE use.
The addition of a subscription model also provides predictable support and lifecycle management for technology deployed across multiple facilities.
