Lately my Apple Vision Pro has started giving very uncomfortable (sometimes even painful) shocks to my right temple when I am wearing it and it is on the charger. At first I thought it was just my imagination; I shave my head, and thought maybe it was just pulling at the short hair. But then I noticed that when I had it on the charger, and was typing on my MacBook Pro, the surface would feel like I was getting haptic feedback. When I unplugged the Vision Pro from the charger, the feeling went away.
Oddly enough, the shocks were coming from the connector where the headband clips on (which is also the metal that touches the skin).
Since I was feeling the shock when I touched the laptop, I decided to put a volt meter between the headset and the laptop. When set to DC voltage, the results were all over the place. So I decided to try AC voltage, and to my surprise, I measured a constant 22v AC (and drops to around 6v when I take it off and the displays turn off). This confused me, as I would not think there would be AC voltage on a USB powered device, especially on the head straps. Maybe there is some kind of sensor there that is not yet in use that is leaking voltage?
Oddly, the shocks primarily come from the right side, not the left, where the power connects to the strap, though I do get the haptic sensation from any of the metal parts on both strips (both the strap connectors and the speakers). Fortunately, the speakers themselves do not actually contact the skin when wearing it normally.
It turns out I am not the only one who has this issue, though it does not seem to be wide spread. Perhaps most people do not work with it while it is connected to a charger, or I am just more sensitive to electricity than most people.
At this point, I thought I had a defective unit and took it to the Apple store. Unsurprisingly, they did not want to touch it with a 10 foot pole, and referred me to the safety team at corporate. They were supposed to contact be, but, also unsurprisingly, did not. So after a few weeks I took it back and had to be a little more assertive. The safety team they called said that it was “perfectly normal” for there to be voltage applied to my temple, but they finally agreed to swap it out for a replacement unit. I was hoping that would be the end of it.
It was not.
The replacement unit does exactly the same thing. So now I am gathering as much information as I can with as many details as I can gather to formally submit a complaint to Apple and see if they will acknowledge it (or just quietly fix it).
My current “solution” to the problem is I created little cloth “socks” by cutting the fingers off of a pair of cloth work gloves that slip over the metal contact and keep it from touching my head. So far, this works.
I did take this image from a Lumafield article that shows the speaker module and that there are, in fact, wires going in the direction of the head strap clip. I can only speculate what those wires are for, but it does validate at least the possibility that the clip is wired up to something.

I am pursuing a contact I have that might be able to get better scans (of the entire strap, not just the speaker) from Lumafield. If I make any headway with that, I will post it here if they allow me to.
If anyone else has this issue, I would love to hear from you with as much detail as you have. As I get more information and do more testing, I will update this accordingly.