Reduce weight on face, offload processing components elsewhere
Even with the elite headstrap, if I wear this on my face for too long, eventually the weight on my forehead causes a pretty bad tension headache.
People are very sensitive to weight on their heads / faces. So I think a better design for the headset would be to offload a lot of the components to a different part, like maybe something you put on your shoulders.
This way, most of the processing and technology rests on your load-bearing shoulders, and the only thing that's on your face is the bare minimum necessary for the screen / vision. Think like just sunglasses with some kind of comfortable attachment to the shoulder piece where the "computer" is.
this will offload most of the weight to the shoulders, and relieve the weight on face / head so that it hurts less.