An optical film fabrication method, an optical film and a head-mounted display are provided. The optical film fabrication method comprises: providing a substrate having a curved surface; dispensing a photo-alignment (PAM) layer on the curved surface of the substrate and exposing the PAM layer to spatially-uniformly polarized light; dispensing a birefringent material layer on the PAM layer; and curing the birefringent material layer to form a birefringent film on the curved surface. An optic axis orientation of birefringent material molecules in the birefringent film are spatially uniform across the birefringent film.