How Ari OS is bringing natural, hands-free interaction to every device in RealWear’s portfolio of wearables
Industrial Wearables Are Entering a New Era
Picture a field worker who discovers a fault on an electrical pole, a valve, a control panel, or out on a remote site, far from the office and the specialists who could help. Traditionally, they’d photograph the fault, note its location, document everything needed to identify the problem, then head back to base to log it all before scheduling a maintenance visit. It works, but it’s slow, and every extra step is time the job doesn’t really need.
This is the problem industrial wearables were built to solve. Field workers need information and expertise while they’re working, not after they’ve stopped to find a phone or tablet. Traditional devices interrupt the task; a remote expert who could resolve the issue in minutes is often based somewhere else entirely. Hands-free wearable technology removes that friction, letting workers stay focused on the task while still staying connected.
But the question facing organisations today has moved on. It’s no longer “should we use RealWear?” It’s “which RealWear device is right for our workforce?” – and, increasingly, what the software running on that device can do for them.
Meet the RealWear Portfolio: Navigator 520, Navigator Z1 and Arc 3
RealWear’s current portfolio covers three distinct devices; each built around a different working environment and use case.
Navigator 520
An established industrial workhorse: rugged, modular and fully hands-free. It remains a strong general-purpose choice for industrial and field-service work.
Navigator Z1
Designed for hazardous environments. It’s intrinsically safe, suited to settings where safety certification is critical, and includes advanced imaging capabilities such as thermal inspection.
Arc 3
A newer, lightweight form factor with a see-through display and a high-resolution visual experience – ideal for workers who need information in their field of view without the bulk of a traditional head-mounted device.
While the hardware is designed for different environments, RealWear’s Ari OS experience is expanding across its device portfolio, with features and capabilities depending on the device and software release.
Navigator 520 vs Navigator Z1 vs Arc 3
RealWear Navigator 520 vs Navigator Z1 vs Arc 3 – Key Specifications
| Specification | Navigator 520 | Navigator Z1 | Arc 3 |
| Best suited for | General industrial work | Hazardous environments | Lightweight assisted reality |
| Chipset | Qualcomm® Snapdragon™ 662 | Qualcomm® Dragonwing™ QCS6490 | Qualcomm® Snapdragon™ 662 |
| Memory | 64 GB / 4 GB RAM / microSD up to 512 GB | 128 GB / 8 GB RAM | 64 GB / 4 GB RAM |
| Weight | 270 g | 383 g | 179 g |
| Operating temperature | −20°C to 45°C | −20°C to 55°C | −20°C to 45°C |
| Ruggedisation | IP66, MIL-STD-810H | Intrinsically Safe (ATEX Zone 1 & CSA C1/D1), IP66, MIL-STD-810H | None |
| Display technology | Liquid Crystal on Silicon (Full-Color RGB) | Liquid Crystal on Silicon (Full-Color RGB) | Micro-OLED (Full-Color, 95% DCI-P3) |
| Resolution | 1280 × 720 (HD) | 1280 × 720 (HD) | 1920 × 1080 (FHD) |
| Field of View | 24° | 24° | 22° |
| See-through display | No | No | Yes |
| Supported eye | Both eyes supported | Both eyes supported | Right eye |
| Main camera | 50 MP | 50 MP | 50 MP |
| Additional camera | — | FLIR Lepton® 3.5 thermal camera | 8 MP wide-angle |
| Video resolution | 1080p at 60 fps | 4K at 30 fps; 1080p at 120 fps | 1080p at 60 fps |
| Battery | Hot-swappable Li-polymer, 2600 mAh | Removable Li-ion, 2560 mAh | Rechargeable Li-polymer, 2000 mAh |
| Wi-Fi | 802.11 a/b/g/n/ac, 2.4 & 5 GHz | 802.11 a/b/g/n/ac/ax, 2.4 & 5 GHz | 802.11 a/b/g/n/ac, 2.4 & 5 GHz |
| Bluetooth | Bluetooth 5.1 | Bluetooth 5.1 | Bluetooth 5.1 |
| Microphones | 4 digital microphones with ANC | 4 digital microphones with ANC | 4 digital microphones with ANC |
| Speaker | Internal 94 dBA | Internal 94 dBA | Internal 85 dBA |
| Operating system | Ari OS (Android 13) | Ari OS (Android 13) | Ari OS (Android 13) |
| Cloud | Ari Cloud | Ari Cloud | Ari Cloud |
| Key advantage | Rugged, modular and hot-swappable | Intrinsically safe with thermal imaging | Lightweight with see-through FHD display |
Navigator 520: The Established Industrial Workhorse
The Navigator 520 is the established rugged platform in the portfolio – designed for organisations that prioritise durability, modularity and full-shift hands-free operation. It’s operated primarily through voice commands, so a technician can access information, navigate applications and speak to colleagues without ever putting down their tools – all while wearing it comfortably alongside standard PPE, thanks to a hot-swappable battery that keeps teams productive through long shifts.
Choose Navigator 520 when the priority is:
- Maintenance and repair work
- Inspection
- Field service
- Remote expert support
- Digital work instructions
- Industrial environments where ruggedisation is important
Navigator Z1: Built for Hazardous Environments
Navigator Z1 exists for one reason: some sites won’t permit a standard electronic device on the floor. It’s intrinsically safe and designed specifically for hazardous environments, suitable for ATEX- and CSA-certified use cases across industrial field service, oil & gas, chemical environments and utilities anywhere inspection and maintenance work happens around flammable gases, vapours or combustible dust.
Beyond its safety credentials, Navigator Z1 pairs a 50 MP camera with a FLIR thermal camera, letting a technician flag a hotspot or fault during inspection and troubleshooting without ever needing to remove their PPE.
RealWear Arc 3: A New Approach to Assisted Reality
The RealWear Arc 3 is a voice-controlled assisted reality headset that gives frontline workers instant access to the information they need, all while keeping their hands free. Worn like a headband, it’s the lightest headset in the RealWear portfolio. Built with a see-through micro-OLED display that brings sharp, detailed visuals to life, without losing sight of the world around them.
The RealWear Arc 3 empowers workers to access documents, capture images, join video calls, and run custom applications – all without touching a screen.
Unlike the Navigator 520 and Z1, Arc 3 uses a see-through display, allowing digital information to appear within the worker’s view while maintaining awareness of the surrounding environment.
Arc 3 suits use cases such as:
- Digital work instructions
- Inspection
- Training
- Remote assistance
- Visual workflows
- Information overlays
- Field-service application
Arc 3 represents a move toward lighter, more visually immersive frontline computing.
Ari OS: A New Direction for Frontline Wearables
Hardware is only part of the wearable experience. RealWear’s Ari OS introduces a more natural way for frontline workers to interact with supported devices and applications. Ari OS is now available on the Navigator 520, Navigator Z1 and Arc 3, with features and capabilities depending on the device and software release.
From Voice Commands to Intelligent Interaction
On a traditional wearable, getting to the information you need looks something like this: say “open application,” navigate a menu, select an option, find the information, then continue working. Each step is a fixed command, in a fixed order.
Ari OS moves in a different direction, allowing workers to interact with the device more naturally. That includes natural-language interaction (“Hey Ari”), system controls, opening applications, getting information, general Q&A, and hands-free calling and collaboration all through ordinary spoken language rather than a rigid command set. It’s worth being precise here: Ari OS is a genuine step forward in natural interaction, not a claim that it can automatically complete every enterprise workflow on its own.
Why Ari OS Matters for Frontline Workers
Less interaction with the device
Workers don’t need to constantly navigate menus to get to what they need.
Faster access to information
Information can be accessed while the worker stays focused on the task in front of them.
Lower cognitive load
Less effort goes into figuring out how to operate the device, and more into the job itself.
Easier adoption
Natural interaction makes wearable technology easier to pick up for new users, reducing the training curve for a new deployment.
Foundation for AI-powered workflows
Perhaps most importantly, Ari OS provides a foundation for increasingly intelligent frontline experiences going forward, rather than a fixed set of features frozen at launch.
Hands-free access to collaboration
Workers can initiate supported collaboration workflows without reaching for a separate phone or tablet, keeping communication closer to the task.
What Ari OS Could Mean in the Field
A few practical scenarios help bring this to life.
Scenario 1 – Maintenance
“Hey Ari, help me with this maintenance procedure.”
The worker can use the wearable to access the relevant information or supported workflow without breaking away from the task.
Scenario 2 – Remote assistance
A technician encounters a problem, starts a collaboration session, and a remote expert sees exactly what the technician sees, offering guidance without needing to travel to the site.
Scenario 3 – Inspection
A technician works through a digital checklist without needing to hold a tablet, capturing information at the point where the work happens.
Scenario 4 – Training
An experienced engineer guides a newer technician remotely, seeing exactly what the trainee sees and making practical, hands-on training accessible even when expertise sits at a different site.
Scenario 5 – Accessing asset information
A technician needs information about an asset while working in the field. Instead of returning to a workstation or searching on a phone, the worker can access supported asset information through the connected application ecosystem while remaining hands-free.
Which RealWear Device Is Right for Your Workforce?
Choose Navigator 520 if:
- You need ruggedisation
- You need modularity
- You need a hot-swappable battery
- General industrial work is your priority
Choose Navigator Z1 if:
- Hazardous-area certification is required
- Intrinsic safety is mandatory
- Thermal inspection is important
- You work in oil & gas, chemical or similarly regulated environments
Choose Arc 3 if:
- Low weight is important
- Visual experience is a priority
- Workers need a see-through display
- You want a newer assisted-reality form factor
What This Means for Industrial Organisations
Reduce downtime
Remote experts can help resolve issues without waiting for travel.
Improve first-time fix rates
Workers can access expertise and digital procedures while performing the job.
Reduce documentation effort
Information can be captured at the point of work.
Accelerate knowledge transfer
Experienced workers can support newer technicians remotely.
Beyond the Headset: Building a Connected Worker
None of these devices delivers its full value in isolation. The real opportunity lies in connecting the worker, the equipment, the information and the expertise – through remote assistance, digital work instructions, enterprise applications, field-service systems, training and inspection workflows.
With Ari OS providing an increasingly intelligent software experience across the current RealWear portfolio, that connection can become more natural: device, software, applications, remote experts and enterprise systems working together rather than as separate tools. That’s what turns a wearable into a genuinely connected-worker strategy, rather than just a piece of hardware.
The Future of Frontline Work Is Intelligent and Hands-Free
The future of frontline wearables isn’t simply about putting a screen in front of a worker. It’s about creating a natural interface between people, information, expertise and enterprise systems. Navigator 520, Navigator Z1 and Arc 3 address different frontline environments, while Ari OS points toward a more intelligent and natural way of interacting with those technologies.
For organisations weighing up their next wearable deployment, the right question isn’t just which device fits the environment – it’s how ready that device is for the more intelligent way frontline work is heading.
Turn RealWear into a Connected-Worker Solution
From RealWear devices and TeamViewer Frontline to SAP and enterprise integration, OnDevice Solutions helps organisations implement connected-worker solutions that bring frontline workers, experts, applications and business systems together.
Whether you’re starting a new RealWear deployment or integrating wearable technology into your existing SAP and field-service landscape, our team can help you plan, implement and connect the solution.
Ready to explore what’s possible?
To explore how the Navigator 520, Navigator Z1 or Arc 3 – and Ari OS – could support your field-service and frontline operations?
Contact On Device Solutions to find the right wearables for your frontline teams and plan a rollout that meets your organisation’s needs.
