You can buy packs of face cushions to replace your existing padding on the HTC Vive. What’s great is that they even come in different sizes; narrow and wide.
The HTC Vive comes with a single Wide Face Cushion pre-installed. The foam is nice and soft, but as I said before, it can get gunked up with sweat and debris from extended use. Foam is also perishable, and susceptible to wear and tear. If it becomes tired and uncomfortable, it’s time to replace it.
They’re not expensive to replace, and as they’re Velcro mounted, you can change them in literally seconds. There are even some pads from third-parties that offer thicker foam, soft leather padding, thin memory foam and more. It’s certainly something worth experimenting as the stock one has plenty of room for improvement.
That being said, if you like the stock foam (I do), having a spare set on hand to replace the worn out one is a great idea. Of course, as Vive suggest, if too much light is entering the VR headset, try using the Narrow Foam Cushion set instead.
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