A hardware project built around the ESP32 microcontroller, combining custom PCB design, 3D-printed mechanical enclosure, and embedded firmware for a miniature 3-axis RGB moving head light.
Quick Stats:
- 🎛️ 3-Axis Motion: Pan, Tilt, Roll (SG90 servos)
- 🌈 RGB LED: 16 million colors (WS2812B addressable)
- 📡 WiFi Control: REST API + web dashboard
- 🔋 Power: USB-C + optional 18650 battery
- 📏 Size: Tennis ball (~6.5cm diameter)
- 💰 Cost: ~$70/unit
- ⏱️ Timeline: 4-5 weeks from start to working prototype
esp32-moving-head-light/
├── firmware/ # ESP32 firmware (PlatformIO)
│ ├── src/
│ │ ├── main.cpp
│ │ ├── config.h
│ │ ├── ServoController.h/.cpp
│ │ ├── RGBController.h/.cpp
│ │ ├── WiFiManager.h/.cpp
│ │ └── WebServer.h/.cpp
│ └── platformio.ini
│
├── hardware/ # PCB schematics, layouts, BOM
│ ├── bom.csv # Bill of Materials (~$70)
│ ├── schematics/
│ └── pcb/
│
├── mechanical/ # CAD and 3D print files
│ ├── cad/ # Fusion 360 / FreeCAD files
│ └── 3d-prints/ # STL files ready for printing
│
├── docs/ # Design documentation & guides
│ ├── design-spec.md # Complete technical specification
│ ├── phase1-setup.md # Environment setup & component testing
│ ├── phase2-firmware.md # Firmware architecture & web interface
│ ├── phase3-mechanical.md # CAD design & 3D printing
│ └── phase4-integration.md # System testing & integration
│
└── README.md # This file
- Design Specification - Full technical spec, component selection, architecture overview
- Bill of Materials - All 25+ components with suppliers and costs
Duration: Week 1-2 | Goal: Verify all components work independently
- Install PlatformIO development environment
- Set up ESP32 breadboard with servos, LED, power
- Test servo control (pan, tilt, roll independently)
- Test RGB LED color control
- Test power detection (USB/battery switching)
- ✅ Outcome: Each component validated and working
Duration: Week 3-4 | Goal: Integrate all components into unified WiFi-controlled system
- Modular firmware design (ServoController, RGBController, WiFiManager)
- WiFi connectivity with auto-reconnect
- REST API for control:
/api/position,/api/color,/api/status - Web dashboard with color picker and position sliders
- OTA (over-the-air) firmware updates
- ✅ Outcome: Fully functional WiFi-controlled moving head light
Duration: Week 2-4 (parallel) | Goal: Design and manufacture custom 3D enclosure
- CAD design of tennis-ball-sized housing
- Servo mounting strategy (pan base, tilt arm, roll motor)
- LED reflector/housing design
- 3D print settings and material selection (PLA)
- Assembly instructions with clips and inserts
- Post-print finishing and testing
- ✅ Outcome: Fully assembled mechanical package
Duration: Week 4-5 | Goal: Complete system validation and manufacturing readiness
- Full system integration (electronics + mechanical)
- Burn-in testing (1+ hour continuous operation)
- Performance metrics (response time, servo precision, WiFi range)
- Environmental testing (temperature, vibration, dust)
- User manual and developer guide
- Manufacturing readiness assessment
- ✅ Outcome: Production-ready prototype
- ESP32-WROOM-32D - WiFi/Bluetooth microcontroller
- 3× SG90 Servos - Smooth 3-axis motion control
- WS2812B RGB LED - Addressable full-spectrum LED
- USB-C Power - Modern power delivery with optional 18650 battery backup
- Custom 3D-Printed Enclosure - Tennis ball sized, modular assembly
- Modular Architecture - ServoController, RGBController, WiFiManager
- REST API - Full HTTP control interface
- Web Dashboard - Intuitive browser-based UI
- OTA Updates - Wireless firmware updates without USB
- WiFi Auto-Connect - Resilient network handling
Web Dashboard:
- Color picker (full RGB spectrum)
- Pan/Tilt/Roll sliders (0-180° range)
- Real-time status display
- Preset animations (optional)
API Endpoints:
GET /api/status- Get current position & colorPOST /api/color?color=#RRGGBB- Set LED colorPOST /api/position?pan=X&tilt=Y&roll=Z- Set servo positions
- Pan (Horizontal): 180°+ rotation via bottom servo
- Tilt (Vertical): 0-180° via side servo on pan arm
- Roll (Spin): 0-180° via servo on tilt arm
All servos controlled independently with smooth interpolation for professional motion.
- WS2812B Addressable RGB LED - 16 million colors
- Parabolic/Conical Reflector - Focuses or diffuses light beam
- Adjustable Brightness - 0-100% power control
- USB-C Input: Direct 5V power (modern, reversible connector)
- Optional Battery: 18650 Li-ion with TP4056 charger module
- Voltage Regulation: Separate 5V rails for servos and logic
- Runtime: 2+ hours on battery
| Category | Qty | Cost/Unit | Total |
|---|---|---|---|
| ESP32 DevKit | 1 | $10 | $10 |
| SG90 Servos | 3 | $4 | $12 |
| WS2812B LED | 1 | $2 | $2 |
| Power Modules | 2 | $4 | $8 |
| Battery & Charger | 1 | $6 | $6 |
| PCB/Breadboard | 1 | $5 | $5 |
| 3D Print Material | - | - | $10 |
| Connectors/Misc | - | - | $7 |
| TOTAL | ~$60-70 |
Hardware:
- ESP32-WROOM-32D (WiFi/Bluetooth SoC)
- SG90 servo motors (3×)
- WS2812B addressable RGB LED
Firmware:
- Arduino framework (C++)
- PlatformIO (build system)
- ESP32 core libraries
- Adafruit NeoPixel (LED control)
- ESP32Servo (motor control)
Development Tools:
- VSCode + PlatformIO extension
- FreeCAD or Fusion 360 (CAD design)
- Cura or Prusaslicer (3D print slicing)
- Git/GitHub (version control)
- Computer with USB port
- USB-C cable
- PlatformIO installed in VSCode
- Basic soldering skills (optional - can use breadboard)
👉 Use Bill of Materials - components available from Amazon/AliExpress
- Phase 1 (Week 1-2): Environment Setup - test components
- Phase 2 (Week 3-4): Firmware Development - build WiFi control
- Phase 3 (Week 2-4): Mechanical Design - CAD & 3D print
- Phase 4 (Week 4-5): Integration & Testing - validate system
1. Power on device via USB-C
2. Connect to WiFi network (SSID: "moving-head-light")
3. Open browser: http://192.168.1.XXX
4. Use color picker & sliders to control
| Phase | Task | Duration | Status |
|---|---|---|---|
| 0 | Design & Specification | 1 week | ✅ Complete |
| 1 | Component Testing | 2 weeks | ⏳ Pending |
| 2 | Firmware Development | 2 weeks | ⏳ Pending |
| 3 | Mechanical Design | 2 weeks | ⏳ Pending |
| 4 | System Integration | 2 weeks | ⏳ Pending |
| Total | 4-5 weeks | In Progress |
- Design specification (technical details, component selection)
- Bill of Materials (suppliers, costs, quantities)
- Phase 1 guide (environment setup, component testing)
- Phase 2 guide (firmware architecture, web server)
- Phase 3 guide (CAD design, 3D printing)
- Phase 4 guide (integration, testing, manufacturing)
- This README
After completing this project, you'll have experience with:
Hardware Design:
- ESP32 microcontroller programming
- Servo motor control (PWM)
- Addressable LED (WS2812B) control
- Power management (USB, battery, voltage regulation)
- Electrical debugging and troubleshooting
Firmware Development:
- Modular C++ architecture
- WiFi connectivity and OTA updates
- REST API design
- Web server implementation
- Embedded systems optimization
Mechanical Design:
- CAD modeling (Fusion 360/FreeCAD)
- 3D printing workflow
- Component integration
- Assembly design
Project Management:
- Requirements specification
- Design documentation
- Testing and validation
- Iterative development
- ESP32 Documentation: https://docs.espressif.com/
- Arduino Framework: https://www.arduino.cc/
- PlatformIO: https://platformio.org/
- Adafruit Tutorials: https://learn.adafruit.com/
- FreeCAD: https://www.freecadweb.org/
- Fusion 360: https://www.autodesk.com/products/fusion-360/
MIT License - Feel free to use, modify, and distribute for personal or commercial purposes.
tillingcode - Full design, firmware, and documentation
Project started: 2026-03-30
Want to improve this project?
- Fork the repository
- Make improvements
- Submit a pull request
- Share feedback and suggestions
For questions or issues:
- Check the relevant phase documentation
- Review Design Specification
- Open a GitHub issue
- Check existing GitHub issues for solutions
Last Updated: 2026-03-30
Version: 1.0.0 - Alpha (Concept & Design Phase Complete)