LED Face Mask Project
Summary
The LED Face Mask Project is Sean Hodgins' ambitious second iteration of a full-face LED display system, documented in the episode "Episode Summary: I Built the Craziest LED Mask". Five years after his original projector-based design, Sean took the concept in a completely different direction by creating a mask where every panel is its own LED matrix. The result is a wearable display featuring 2,960 individually addressable LEDs mounted on custom PCB panels that conform to the 3D shape of a face. Based on a Wintercroft rabbit design, the mask can display animations, images, and videos across its irregular surface geometry. The project represents a convergence of PCB design, 3D soldering techniques, LED programming, and power management, resulting in a mask that can run for up to 9 hours on a single battery charge.
Details
The Mark 2 LED mask fundamentally reimagines the original concept. Rather than using a projector to illuminate a white mask surface, Sean designed the new version around the principle that every panel of the mask would be its own LED matrix. This architectural decision required custom PCB panels shaped to match each facet of the Wintercroft rabbit mask template, with LEDs arranged in a grid pattern on each board.
The technical specifications are substantial: the mask incorporates exactly 2,960 LEDs across its surface. As Sean noted in the episode, "There are almost too many LEDs to count on this mask, but I know the number because I had to do it. 2960." The procurement process itself was bold—Sean chose to "irrationally order 9,000 LEDs on Alibaba" to ensure he had sufficient components for the build and potential future iterations.
The electrical architecture centers on addressable LED technology, which allows each individual LED to be controlled independently. The mask can be driven by two different controller systems: Pixelblaze, a dedicated LED controller, or a Raspberry Pi for more complex processing and video playback. The irregular geometry of the mask panels presents a unique challenge—unlike a flat LED matrix or regular grid, the mask's LEDs are arranged across multiple planes and angles, requiring custom mapping software to translate 2D images and videos into the correct positions on the 3D surface.
Power management was a critical consideration. The mask runs on a 3S lithium battery configuration, and Sean optimized the power consumption to achieve impressive runtime. As he enthusiastically reported: "I'm ready for 9 hours of face Waring goodness," indicating the mask can operate for an extended period despite powering nearly 3,000 LEDs.
Manufacturing the mask required sophisticated PCB fabrication from PCBway, who produced the custom-shaped circuit boards that form each panel. The assembly process involved 3D soldering techniques to connect the individual panels into a cohesive system while maintaining the mask's structural integrity and wearability.
The project documentation includes full schematics and code available on GitHub under the repository name "black_rabbit," allowing others to replicate or modify the design. The mask's capabilities extend beyond simple patterns—it can display full animations and video content, effectively turning the wearer's face into a dynamic screen.
History
I Built the Craziest LED Mask
The entire episode chronicles the development and construction of the LED Face Mask Project. Sean Hodgins begins by explaining that this is his second attempt at creating an LED mask, with the first version having been built five years prior using a completely different approach with a projector system.
The episode documents Sean's decision to fundamentally change the design philosophy. Rather than projecting onto a passive surface, he decided to make every panel of the mask its own active LED matrix, leading to the massive undertaking of integrating 2,960 individual LEDs. He walks through his procurement of 9,000 LEDs from Alibaba—an intentionally excessive order that speaks to both his commitment to the project and his planning for potential failures and future projects.
Throughout the episode, Sean details the technical challenges of creating custom PCB panels that match the geometric shapes of the Wintercroft rabbit mask template. He explains the complexities of LED mapping for such an irregular surface, demonstrating how he developed software to correctly translate standard image and video formats onto the mask's non-planar array of LEDs.
The power system design receives significant attention, with Sean explaining his choice of a 3S battery configuration and his optimization work to achieve the 9-hour runtime he ultimately achieved. He discusses the options for controlling the mask, comparing the Pixelblaze controller system with Raspberry Pi-based approaches.
The manufacturing partnership with PCBway is highlighted as critical to the project's success, as they produced the custom-shaped circuit boards that form the mask's structure. Sean demonstrates the 3D soldering techniques required to assemble the panels into a wearable form factor while maintaining electrical connections across the entire array.
By the episode's conclusion, Sean has a fully functional mask capable of displaying complex animations and videos, with the project files available on GitHub for anyone interested in building their own version or exploring the technical details of the design.