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I think if your new glasses cause headaches your optometrist might have fucked up something, either your prescription/diagnosis or the tech who installed the lenses in the frame didn't center them to your IPD/distortion angle correctly.

Not necessarily true. Sometimes new prescriptions can take some time to adjust to if it's been a long time since the last prescription. Once you settle in they are 100% rock solid but it can be a few days of weirdness as your eyes adjust.

The biggest thing is that your eyes will naturally "strengthen" to make up for loss of acuity with an old prescription and a new prescription will correct that immediately and thus you end up with a mismatch that takes awhile to settle.

I have an HTC Vive and I've experienced headaches and nausea from VR at different times. After that I'll take a long break. And then after a while I forget how bad it felt and try VR again and then have the negative response and take another long break. I never did get my VR legs.

I need to look more into tweaking the eye width on the device.

If it is, then returns of the product will be pretty normal too.