Has anyone in the community thought about creating custom fitted foam pads by using photogrammetry and foam 3D printing? I would think that even a not-so-great scan of a face would produce a pad that is more closely fitted to any one particular face compared to the standard pads. The geometry of this custom pad could be easily calculated by trimming the volume of space between the HMD placed at an optimal distance from the face and the 3D surface of the face.
This could be offered as a service where people would submit multiple photos from various angles to be assembled into a 3D head/face scan. Upon approval of the 3D geometry, the 3D printed foam would be printed for the customer (after a down-payment). Considering that VRCover sells their “dumb” pads for as much as they do, I’d bet people would spend significantly more for a super comfortable, fitted alternative. I know I would.
The main question here is around the 3D printing of foam. The last link I provided seems to indicate it’s doable.