Choosing the right AR guidance device is critical for safety, productivity and quality in industrial operations. With options ranging from HoloLens and Apple Vision Pro to smart glasses, tablets and mobiles, decision makers face a complex landscape. This comparison provides a clear, practical view for operations, HSE, maintenance and training leaders.
AR guidance devices in industry: context and trends
Augmented reality (AR) is no longer experimental in industry. AR guidance devices now support:
- Digital work instructions for technicians and operators
- Remote collaboration with experts during troubleshooting
- Step-by-step SOPs for inspections, maintenance and assembly
- Onboarding and upskilling of new team members
Industrial companies are investing in AR to address skills shortages, reduce incidents, and increase uptime. According to ABI Research, AR in enterprise training and maintenance was projected to surpass $6 billion in annual revenue by 2022. The pandemic accelerated adoption, with hands-free solutions and remote support seeing the fastest growth.
But which AR hardware is best for real-world industrial environments? The answer depends on use case, environment, safety needs, and workforce acceptance. Below, we compare HoloLens, Apple Vision Pro, smart glasses, tablets and mobiles as AR guidance devices for industrial work.
Why the choice of AR device matters now
The right AR device can mean the difference between a successful digital transformation and a stalled pilot. Industrial teams need tools that:
- Enable hands-free, accurate work in PPE and harsh conditions
- Withstand dust, moisture, vibration, and temperature extremes
- Deliver clear visuals and audio in noisy, variable environments
- Integrate with existing workflows, SOPs and IT systems
- Meet safety and regulatory requirements
Device selection impacts:
- Operator safety (especially in hazardous areas)
- Productivity and error rates
- Training effectiveness and knowledge transfer
- Total cost of ownership (hardware, support, upgrades)
As AR hardware matures, decision makers must weigh new options like Apple Vision Pro against established devices such as HoloLens 2, as well as smart glasses, tablets and mobiles.
Comparing HoloLens, Apple Vision Pro, smart glasses, tablets and mobiles for AR guidance
Below, we break down the main device categories for AR guidance in industrial settings.
HoloLens (Microsoft)
Strengths:
- True mixed reality: overlays 3D holograms on the real world
- Hands-free operation with advanced gesture, voice and eye tracking
- Large field of view and spatial mapping
- Enterprise integrations and robust developer ecosystem
- Proven in manufacturing, energy, and field service
Limitations:
- Bulky and heavy for long shifts
- Battery life ~2â3 hours of active use
- Not certified for ATEX or explosive environments
- High upfront cost (typically âŹ3,500ââŹ4,000 per unit)
- May not fit comfortably with all PPE (e.g. hard hats, respirators)
Typical use cases:
- Complex assembly guidance
- Remote expert assistance
- Digital inspections and maintenance SOPs
- Training simulations
Apple Vision Pro
Strengths:
- High-resolution displays and advanced eye tracking
- Intuitive spatial computing with hand and voice input
- Exceptional video passthrough quality for AR overlays
- Strong content ecosystem, especially for 3D visualization
Limitations:
- Designed primarily for office and creative use, not industrial
- Heavy (over 600g) and not ruggedized
- No certification for industrial safety or PPE compatibility
- Short battery life; tethered battery pack
- High cost (âŹ3,700+ per unit)
- Not tested in harsh environments (dust, water, impact)
Potential use cases:
- Design reviews and digital twins in safe, controlled settings
- Training simulations and collaborative planning
- Visualizing complex procedures in R&D labs
Smart glasses (e.g. RealWear, Vuzix, Epson)
Strengths:
- Lightweight, wearable and designed for industrial use
- Hands-free, voice-controlled operation (RealWear HMT-1 is IP66 rated)
- Compatible with hard hats and safety glasses
- Long battery life (8+ hours)
- Lower cost than HoloLens or Vision Pro (âŹ1,000ââŹ2,000)
Limitations:
- Small display (monocular or limited FOV)
- Limited 3D or spatial AR (mostly 2D overlays or video)
- Lower processing power and graphics quality
- Some models have limited camera resolution
Typical use cases:
- Step-by-step digital work instructions (AR SOPs)
- Remote expert video calls
- Inspections and audits
- Simple data capture (photos, videos, checklists)
Tablets (iPad, rugged Android)
Strengths:
- Large, high-resolution displays
- Familiar form factor for most teams
- Wide range of AR apps and integrations
- Can be ruggedized for industrial use
- Moderate cost (âŹ500ââŹ1,500)
Limitations:
- Not hands-free; must be held or mounted
- Can be dropped or damaged in tough environments
- Not compatible with all PPE
- Less suitable for complex, immersive AR
Typical use cases:
- Digital SOPs and checklists
- Visual asset management
- Guided inspections and documentation
- Training modules
Mobile phones (smartphones)
Strengths:
- Ubiquitous and familiar to all teams
- Good cameras and processing power
- Wide app ecosystem
- Low incremental cost (often BYOD)
Limitations:
- Not hands-free
- Small screen size; limited AR immersion
- Prone to drops and damage
- Not suitable for hazardous or gloved environments
Typical use cases:
- Quick reference for digital instructions
- Scanning QR codes and checklists
- Remote expert calls
- Reporting and documentation
At-a-glance: device comparison table
| Device category | Hands-free | Ruggedized | AR immersion | PPE compatible | Typical cost | Battery life | Best for |
|---|---|---|---|---|---|---|---|
| HoloLens | Yes | Moderate | High | Limited | High | 2â3 hrs | Complex 3D guidance, training |
| Apple Vision Pro | No | No | Very high | No | Very high | 2 hrs | Design, simulation, controlled lab use |
| Smart glasses | Yes | Yes | Lowâmedium | Yes | Medium | 8+ hrs | SOPs, inspections, remote support |
| Tablet | No | Some | Medium | Some | Medium | 6â10 hrs | Digital SOPs, training, documentation |
| Mobile phone | No | No | Lowâmedium | No | Low | 6â12 hrs | Quick tasks, reporting, reference |
How AI and ARâguided work instructions perform on each device
The effectiveness of digital work instructions depends not just on software, but on the fit between device and real-world workflow.
HoloLens: advanced AR guidance, but with comfort trade-offs
HoloLens excels at projecting interactive 3D instructions directly onto equipment. This enables:
- Visual step-by-step overlays for assembly or repair
- Animated parts, arrows, and warnings in the technician's view
- Hands-free operation, critical for safety and efficiency
However, the weight and fit can be a barrier for long shifts. HoloLens is best suited for:
- High-value, low-frequency tasks where error reduction is critical
- In-depth training of new or rotating staff
- Environments where 3D spatial guidance adds measurable value
Apple Vision Pro: immersive AR, but not industrial-ready
Apple Vision Pro offers unmatched display clarity and intuitive controls, but lacks industrial features:
- No ruggedization or PPE compatibility
- Short battery life and high cost
- Limited integration with industrial systems
For now, Vision Pro is more suited to design, simulation, and R&D than field operations. Industrial buyers should monitor its evolution, but current models do not meet safety or durability needs.
Smart glasses: practical for daily SOPs and remote support
Smart glasses like RealWear and Vuzix deliver:
- Voice-controlled, heads-up display of digital work instructions
- Easy integration with existing safety gear
- All-day battery life
While the display is less immersive, these devices are proven in real industrial settings for:
- Guided maintenance and inspections
- Stepwise SOPs
- Live video support from remote experts
Tablets and mobiles: versatile, but not hands-free
Tablets and mobiles are ideal for:
- Training, documentation and quick reference
- Asset management and reporting
- Use in non-hazardous, clean environments
They are less suited for tasks that require both hands, or where PPE is mandatory. Ruggedized models extend their use, but do not match the hands-free safety of wearable AR.
Practical examples: AR guidance device selection in action
Example 1: chemical plant maintenance
A chemicals company needs to digitize maintenance SOPs for pump inspections. Key requirements:
- ATEX certification (explosive environment)
- Technicians must wear gloves, goggles, and respirators
- Long shifts (8+ hours) in noisy, dusty conditions
Best fit: Smart glasses (e.g. RealWear HMT-1Z1, ATEX-rated). HoloLens and Vision Pro are not certified for explosive zones; tablets and mobiles are not hands-free.
Example 2: aerospace assembly training
An aerospace OEM wants to train new technicians on complex assembly procedures. Needs:
- 3D visualization of parts and sequences
- Interactive, hands-free guidance
- Integration with PLM systems
Best fit: HoloLens. Delivers immersive, spatial AR with integration options. Vision Pro could be considered in the future for training labs.
Example 3: utility field service
A utility operator needs to enable field engineers to access digital SOPs and remote support during equipment troubleshooting.
Best fit: Smart glasses for daily field use. Tablets for documentation and reporting. HoloLens for advanced, infrequent interventions.
Key criteria for device selection
When evaluating AR guidance devices, industrial decision makers should consider:
- Safety: Does the device support safe operation in your environment? Is it compatible with required PPE?
- Hands-free usability: How often do technicians need both hands free? Is voice control reliable in your conditions?
- Durability: Is the device rugged enough for dust, moisture, vibration, or hazardous areas?
- Display quality: Is the AR content readable and useful in real-world lighting?
- Integration: Can it connect to your digital SOPs, asset management and training systems?
- Total cost: Factor in hardware, support, maintenance, and replacement cycles.
- Change management: Will teams adopt the device? Is onboarding straightforward?
Note: Involve end users in pilot testing. Field engineers, operators and trainers can provide practical feedback on comfort, usability and acceptance.
What ActARion brings to AR guidance device selection
ActARion supports industrial companies through every stage of AR guidance deployment:
- Independent device assessment: We help you select the right AR hardware for your environment and workflows, not just the latest trend.
- Content adaptation: Our AI and ARâguided work instructions are optimized for each device class, ensuring clarity and usability whether on smart glasses, HoloLens or tablets.
- Integration: ActARion connects AR SOPs with your existing EHS, maintenance and training systems, so data flows seamlessly.
- Change management: We provide governance frameworks, user training and adoption support, reducing resistance and maximizing ROI.
- Proof of value: Pilots are structured to deliver measurable results in safety, productivity and knowledge transfer.
Our team has delivered AR projects in manufacturing, energy, chemicals, aerospace and utilities. We understand the regulatory, operational and human factors that drive success.
Explore AR guidance device selection in your organisation
Selecting the right AR guidance device can significantly improve safety, productivity and workforce readiness. To understand which option fits your specific processes and environment, schedule an exploratory call with ActARion. There is no commitmentâjust practical insight into device options, pilot approaches and measurable outcomes.
Learn more about AR onboarding for industrial technicians, or see how digital work instructions improve compliance and quality. For an external overview of AR device trends, see IDCâs latest AR/VR device market update.