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Carl Bugeja’s Mini Sphere packs 945 LEDs into a roughly 6-centimeter, baseball-sized display. Five repeated, four-layer flexible PCB panels wrap a 3D-printed geodesic support to create its curved surface. It can show programmed animations and emoji-like graphics, and respond to being picked up or shaken—but it is a tiny maker display, not a high-resolution miniature of the Las Vegas venue.

How the miniature sphere is built

The main engineering challenge is distributing addressable LEDs across a curved surface while routing power and data. Bugeja’s design uses five repeated flexible PCB panels, each shaped to fit a triangular facet in a geodesic arrangement. A 3D-printed dome and base support the panels as they form the sphere. Hackster reports a diameter of about six centimeters, with 945 LEDs and 305 capacitors across the four-layer boards (Hackster.io; Hackaday).

Yanko Design identifies the LEDs as SK6805 parts measuring 1 mm × 1 mm and names a CodeCell controller with USB-C power (Yanko Design, April 30, 2024). Because the surface consists of separate facets, graphics have to be mapped across the panels rather than laid out as if the display were one ordinary flat screen.

What it displays—and where image quality runs out

The Mini Sphere runs programmed patterns and graphics, including emoji-like images, and can react when picked up or shaken. A translucent diffuser softens the gaps between individual pixels, helping the light read as a more coherent image.

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That treatment does not make the display high resolution. Hackaday reports that sharp lines and borders are difficult to render cleanly, and familiar shapes such as circles or eyes can look ragged. With 945 LEDs on a small curved object, the project is best understood as an animated desk display, not a monitor or a functional equivalent of the venue’s screen.

Prototype lessons and reported cost

Early versions had real reliability issues: Hackaday reports an initial board with an unfixable short, followed by problems with adhesive and durability. Hackster says temperature and humidity affected the adhesive’s tack over time. Under Bugeja’s conditions, a short bake-out before mounting the flexible PCB improved its grip. That is a report of this build’s experience, not a universal flex-PCB process recommendation.

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Hackster and Hackaday each put the one-off project or bill of materials at roughly $250. Hackaday’s May 31, 2024 estimate includes components, PCB, controller, and mechanical parts. This is a historical reported build estimate, not a current parts quote; present component and fabrication prices may differ.

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Keep this build distinct from other MiniSphere projects

Another project called MiniSphere, by OK Design on Hackaday.io, is a separate build with different specifications. Its page describes a 75 mm sphere with 1,080 LEDs, ten flexible panels, a battery pack, IMU, and UWB radio (Hackaday.io). Those details do not describe Bugeja’s Mini Sphere.

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