Scroll to take it apart
Every part, every file.
48 boards, no two alike. Trapezoids and triangles cut to the head, a printed shell, five cameras, and a knit beanie over all of it.
1,273dry gold contacts, no gel
89.5%of the scalp under a board
48contact boards, every one a different shape
5cameras: three front, two on the back rim
54 hto print the shell
1,273 contacts. All of them gold.
Seen from the scalp: one off-the-shelf gold spring pin on every contact. Each board is small enough that 3 mm of spring reaches the scalp from all of its pins.
Real boards, real parts.
A spring pin reflowed on every contact, a buffer behind it, an ADS131M08 for every eight, an RP2040 controller stacked 1.5 mm behind on four DF40 pairs.
The hub.
Twenty-one cable ports, two RP2350s, an ESP32-S3 for Wi-Fi, USB 2.0 through an FT2232H, and a 2000 mAh high-discharge cell under the pod cover.
Five cameras.
Three across the front, two on the slanted back rim, each lens through a grommet in the knit with a microphone beside it.
Everything to build one.
Bill of materialsEvery part, counted from the design
Plans and files3D parts, board files, the pin to buy
Design notesHow and why it is built this way
Where it stands
| part | what it is | state | |
|---|---|---|---|
| Layout | 48 boards cut to the head, 1,273 contacts, 89.5% of the scalp | every contact inside the pin's range; clearances checked in 3D | done |
| Contact boards | spring pin, divider, buffer and coupling per contact; an ADS131M08 per eight | 48/48 routed and checked, Gerbers, BOM, CPL | done |
| Controllers | RP2040, flash, crystal, LDO, hub and filler FPCs, on four DF40 pairs | 16/16 routed and checked | done |
| Hub EXO-430 | reference and bias, clock, 16 controller and 5 camera ports, battery, USB-C, Wi-Fi | routed and checked | done |
| Cameras EXO-450 | ESP32-S3 module, OV2640 wide-angle camera, PDM mic, MJPEG over Wi-Fi | routed and checked | done |
| Shell EXO-140…144 | PETG on an Ender-3 V3 SE, split crown and bands, hub pod, standoffs at every board | 64/64 checks pass | done |
| Cost | $11,784.02 for one helmet, every part an exact line | JLC fees from their published rules | done |