Unicorn Horn with 3D Printing & NeoPixel LEDs

Searching for a simple costume project to bring your Unikitty or Lady Rainicorn to the next level? 3D print a flexible unicorn horn and illuminate it from within with NeoPixels and a GEMMA M0, GEMMA v1 or GEMMA v2 based microcontroller. Or forget the electronics and use glow in the dark NinjaFlex filament for a green glow with no batteries required.

This is a pretty quick soldering project that is suitable for attentive beginners! Prerequisite guides:

For this project you will need:

Unicorn glamour shots by Andrew Tingle.

3D Printing the Horn

Download the printable unicorn horn file from Thingiverse: Adafruit Unicorn Horn

To print the unicorn horn, the 3D printer will need to be capable of printing a minimum of 140mm tall. The diameter of the horn is 40mm x 48mm, which should be enough to fit on most beds, such as the Printrbot Simple Metal.

For 3D printing with Ninjaflex material, we recommend using a printer with a direct direct, spring loaded extruder. The horn can be printed in PLA, ABS and other filaments.

For the best quality when printing with NinjaFlex, we recommend the following slicing settings:

  • Retraction: Off
  • Speeds: 90/150
  • Extruder Temp: 230c
  • Infill 10%
  • Raft+Support: Off
  • No Heated Bed

Print time is approximately 3 hours.

From left to right: translucent, white, glow in the dark, white

Circuit Diagram

Two NeoPixel sticks are wired in parallel to GEMMA:

  • GEMMA GND to NeoPixel sticks GND
  • GEMMA D1 to NeoPixel sticks DIN
  • GEMMA Vout to NeoPixel sticks 4-7VDC
  • 500mAh battery connected to GEMMA’s JST port
  • GEMMA’s on/off switch used to toggle power

Arduino Code

Here’s a simplified version of the NeoPixel sample code that just cycles a slow rainbow on eight pixels connected to D1:

#include <Adafruit_NeoPixel.h>

#define PIN 1

// Parameter 1 = number of pixels in strip
// Parameter 2 = Arduino pin number (most are valid)
// Parameter 3 = pixel type flags, add together as needed:
//   NEO_KHZ800  800 KHz bitstream (most NeoPixel products w/WS2812 LEDs)
//   NEO_KHZ400  400 KHz (classic 'v1' (not v2) FLORA pixels, WS2811 drivers)
//   NEO_GRB     Pixels are wired for GRB bitstream (most NeoPixel products)
//   NEO_RGB     Pixels are wired for RGB bitstream (v1 FLORA pixels, not v2)
Adafruit_NeoPixel strip = Adafruit_NeoPixel(8, PIN, NEO_GRB + NEO_KHZ800);

// IMPORTANT: Avoid connecting on a live circuit...if you must, connect GND first.

void setup() {
  strip.begin();
  strip.setBrightness(100); //adjust brightness here
  strip.show(); // Initialize all pixels to 'off'
}

void loop() {
  rainbowCycle(20);
}


// Slightly different, this makes the rainbow equally distributed throughout
void rainbowCycle(uint8_t wait) {
  uint16_t i, j;

  for(j=0; j<256*5; j++) { // 5 cycles of all colors on wheel
    for(i=0; i< strip.numPixels(); i++) {
      strip.setPixelColor(i, Wheel(((i * 256 / strip.numPixels()) + j) & 255));
    }
    strip.show();
    delay(wait);
  }
}



// Input a value 0 to 255 to get a color value.
// The colours are a transition r - g - b - back to r.
uint32_t Wheel(byte WheelPos) {
  if(WheelPos < 85) {
   return strip.Color(WheelPos * 3, 255 - WheelPos * 3, 0);
  } else if(WheelPos < 170) {
   WheelPos -= 85;
   return strip.Color(255 - WheelPos * 3, 0, WheelPos * 3);
  } else {
   WheelPos -= 170;
   return strip.Color(0, WheelPos * 3, 255 - WheelPos * 3);
  }
}

Installing Arduino libraries is a frequent stumbling block. If this is your first time, or simply needing a refresher, please read the All About Arduino Libraries tutorial.If the library is correctly installed (and the Arduino IDE is restarted), you should be able to navigate through the “File” rollover menus as follows:

File→Sketchbook→Libraries→Adafruit_NeoPixel→strandtest

Connect up your NeoPixels in a solderless breadboard and use alligator clips to attach to GEMMA, referring to the circuit diagram if necessary.

You’ll need to change a few lines in the code regarding the data pin (1), type of pixels (RGB vs GRB), and number of pixels (5). The resulting (and slightly simplified) code is below:

From the Tools→Board menu, select the device you are using:

  • Adafruit Gemma M0
  • Adafruit Gemma 8 MHz 
  • Connect the USB cable between the computer and your device. The original Gemma (8 MHz) need the reset button pressed on the board, then click the upload button (right arrow icon) in the Arduino IDE. You do not need to press the reset on the newer Gemma M0 or Trinket M0.

When the battery is connected, you should get a light show from the LEDs. All your pixels working? Great! You can take apart this prototype and get ready to put the pixels in the collar. Refer to the NeoPixel Uberguide for more info.

Sew Headband

For the headband version, measure two pieces of grosgrain ribbon to fit your skull, and mark/cut to length. The hair elastic will make up for the lack of seam allowance.

Using a zigzag stitch on your sewing machine, stitch the edges of the ribbons together leaving the last 1.5 inches unstitched.

Fold over the raw ends around a hair elastic and stitch in place for a stretch fit!

If you don’t plan to add electronics, you can make the headband with just one piece of ribbon.

Fold the headband in half and crease it at the mid point, then hand stitch the horn in place through the sew tabs and wear.

Assemble and Test Circuit

Set up your NeoPixel sticks in a pair of helping hands with the input ends facing you and close to one another.

Tin the pads with solder and connect one ground to another with a small piece of silicone coated wire. Also solder on a long wire to another ground pad, to extend to GEMMA.

Similarly solder up parallel connections between the pairs of digital inputs and power pads according to the circuit diagram. Take care where two wires are soldered to the same pad to avoid shorts.

If you’re making a headband, snip a hole in the outer layer of ribbon at the front center and thread the long wires through to the back of the headband. Use a seam ripper to open up the zigzag stitching a bit to get the wires out and make room for the GEMMA and battery. Solder the three wires to GEMMA according to the circuit diagram.

If you’re making a baseball cap, cut a hole in the front with a seam ripper and thread the long wires through before soldering to GEMMA.

Upload the rainbow sample code to GEMMA with the Arduino Code. This will allow confirmation that your solder joints are solid before sticking the NeoPixel sticks together, back to back, using double-stick foam tape.

Attach Horn

Use an optional tuft of fiberfill to help keep the sticks centered within the horn, and place inside. Rotate the assembly until you’re happy with the arrangement.

Thread a needle, double over the thread, and knot the ends together. Hand stitch each sew tab and knot/cut the thread individually.

Inside the cap, tack the wires down along their way to the GEMMA and battery inside the trim.

Wear it!

Use GEMMA’s onboard on/off switch to toggle the circuit’s power. This project is fun with or without electronics, make one to fit your costume’s style!

Consider further protecting the circuit with a coating or covering if you plan to be very active/sweaty or in wet conditions. Tips on that can be found in this video:

Originally posted on Adafruit

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