EPCOT NeoPixel Lamp

Build your own IoT NeoPixel lamp inspired by Disney's EPCOT Spaceship Earth! Use a QT Py ESP32 PICO, NeoPixel BFF Driver, and WLED (web-based LED control software) to make amazing lighting effects!

Mobile Device Control

Using the WLED firmware, the project controls LED animations using a mobile phone! You can pick from dozens of beautiful animations and use the Presets feature to create your own playlists.

3D Printed Geodesic Sphere

The geodesic sphere is split into two halves that are joined with neodymium magnets. A total of 156 NeoPixel LEDs are hot glued to the various points and connected via JST plugs. The parts are 3D printed without any support material.

CAD Parts List

STL files for 3D printing are oriented to print "as-is" on FDM style machines. Parts are designed to 3D print without any support material using PLA filament. Original design source may be downloaded using the links below.

• sphere-top.STL
• sphere-bottom.STL
• sphere-cover.STL

Build Volume

The parts require a 3D printer with a minimum build volume.

• 228mm (X) x 202mm (Y) x 118mm (Z)

Visit https://install.wled.me/

Plug your microcontroller into your computer with a known good power+data USB cable. Click "Install" and select the port for your board.

Depending on the USB-to-serial bridge chip on the board, you might see one or two serial ports. On Mac, for instance, there might be both “/dev/cu.usbmodem[number]” and “/dev/cu.wchusbserial[number]”. Use the “wchusbserial” one.

WiFi Setup

In the WLED interface, locate and click on the Config icon in the top menu. Then, click on the WiFi Setup button. Under the mDNS address section, enter a desired name for your project. This will make connecting to your project from the web browser easier.

Click the Save button when finished.

LED Preferences

Use the Back button in the top menu and click on the LED Preferences button.

Under Length, enter 156 in the textbox.

Under GPIO, enter 15 into the textbox.

Click the Save button when finished.

Wiring USB-C Breakout

Measure and cut the USB-C cable so it's 4 inches (10cm) in length.

Using a wire stripper, remove about an inch of insulation to expose the four colored wires. Strip some insulation from their tips.

Solder the four wires to the following pins on the USB-C Breakout:

• Green wire to D+ pin
• White wire  to D– pin
• Black wire to GND pin
• Red wire to VBUS pin

Solder Headers to QT Py & BFF

QT Py and BFF boards are connected "belly-to-belly".

Install and solder two 1x7 socket female headers to the NeoPixel BFF Driver board's bottom side.

Install and solder two 1x7 male header pins to the QT Py ESP32 Pico's bottom side.

Install QT Py to BFF

Orient the QT PY ESP32 Pico with the NeoPixel BFF Driver board so the USB port is lined up with the 2-pin JST PH connector.

Plug in the QT PY ESP32 Pico to the NeoPixel BFF Driver board.

Hardware for Bottom Cover

Use the following hardware to secure the USB-C Breakout board to the bottom cover.

• 2x M2.5 x 10mm long screws
• 2x M2.5 hex nuts

Secure USB-C Breakout

Place the USB-C breakout PCB over the standoffs on the bottom cover.

Insert and fasten the screws through the mounting holes. Use the hex nuts to secure the USB-C breakout.

Solder LED Strips for Bottom Half

The bottom half of the sphere will need 85 NeoPixel LEDs. Connect two LED strips together by soldering their wires. Make sure the DATA OUT wire connects to the DATA IN wire. Cut the joined strips so it has a total of 85 LEDs. Replace the first LED's connector with the 3-pin JST PH connector. Use heat shrink tubing to insulated the exposed wire.

Soldering Connector for Bottom Half

Solder the 3-pin socket connector to the end of the strip. Use heat shrink tubing to insulate the exposed wire.

Solder LED strips for Top Half

The top half of the sphere is need 71 NeoPixel LEDs. Solder two LED strips together and cut the joined strip so it only has 71 LEDs. Solder the 3-pin plug connector to the first LED in the strand. Use heat shrink tubing to insulate the exposed wire. 

Install Magnets into Bottom Half

Insert and glue a magnet into a magnet tab in the bottom half of the sphere. Allow the glue to dry before continuing to the next tabs.

Install Magnets in Top Half

Check polarity of the magnets for the top half of the sphere before installing.

Insert and glue a magnet into a magnet tab in the top half of the sphere. Allow the glue to dry before continuing to the next tabs.

Install LED Strip to Bottom Half

Start hot glueing the 85x NeoPixel LED strip to the bottom half of the sphere. 

Install the first NeoPixel LED to the hole closest to the slot.

Add a small drop of hot glue to the hole. Then, carefully place the LED onto the hot glue and hold for a few seconds.

Repeat this process, going in a spiral direction until all LEDs are hot glued.

Glue Bottom Strip Edges

NeoPixel LED #66 – #85 will need to be glued to the edge of the sphere's bottom half.

Lean the dome on it's side to prevent the hot glue from drooping down. Add a small drop of hot glue to the hole halves and carefully place the LEDs onto the edge. Hold for a few seconds to allow the hot glue to dry. 

Repeat this process until all LEDs are glued to the edges. 

Glued Bottom Strip

Take a moment to check all of the NeoPixel LEDs have been properly hot glued to the holes.

Install LED strip to Top Half

Start attaching the second LED strip to the top half of the sphere beginning with the first LED hot glued to the edges. Then, continue attaching in a spiral direction.

Connect Strip to BFF

Grab the 3-pin JST PH connector from the bottom LED strip and plug it into the NeoPixel BFF driver board.

Connect USB to QT Py

Grab the USB-C cable from USB-C breakout that's secured to the bottom cover and plug it into the QT Py's USB-C port.

Install QT Py & BFF

Insert the QT Py and NeoPixel BFF into the center of the bottom half.

Installed QT Py & BFF

Pull the QT Py & NeoPixel BFF driver board through the top of the center pillar. It should freely stay in place.

Install Bottom Cover

Orient the bottom cover with the center pillar of the bottom half so the USB port is aligned with the USB cut out.

Secured Bottom Cover

Firmly press the edges of the bottom cover so they snap fit into the center pillar of the bottom half of the sphere.

Connect Strips

Grab the 3-pin connectors from the top and bottom strips and then plug them together.

Connected Strips

Orient the two halves so the order of the strips allow the continuity of the spiral direction.

Closing Halves

Carefully join the two halves together, making sure all of the wires and connectors are fitted inside the sphere.

Closed Dome

Congratulations on your build! Connect a USB-C cable to the USB-C breakout and provide power using a 5V 2A USB power supply.

Color Picker

The Color tab allows you to pick solid colors with no effects. The gradient slider below the color wheel allows you to adjust the brightness.

Effects

The Effects tab allows you to click from a list of built-in animations. Scroll through the list to see more animations. Click on an effect to activate it immediately.

Each effect will have sliders to adjust parameters such as speed, size, and rate. Click and drag the slider to adjust the setting.

Presets

Presets allow you to save effects. This is a nice way to quickly trigger your favorite animations from the long list of effects. 

Click the +Preset button to add an active animation (the current effect that is running).

Your saved effects will show up in a list under the Presets section.

Playlists

Playlists allows you to group together animations from your saved preset.

Click the +Playlist button to create a playlist. Enter a title into the text box.

Click on the dropdown menu to select an effect from the list of presets.

Enter a desired value in the Duration text box to set how long to play the effect.

Enter a desired value in the Transition text box to set how long to blend from one effect to the next.

Click the + button next to the effect title to add another preset.

Click the save button when finished setting up your playlist.

Click on the Playlist Bubble to activate and playback the playlist.