Methods of assembling a head-mounted display (HMD) may include coupling a first digital projector assembly to an HMD frame, coupling a second digital projector assembly to the HMD frame, and then warping the HMD frame to optically align the first digital projector assembly with the second digital projector assembly. The warped HMD frame may be fixed such that the first digital projector assembly and the second digital projector assembly are optically aligned to within a predetermined threshold. Various other methods and systems are also disclosed.