Actuating Ironman Helmet With Integrated UV Light Sensor

The purpose of this lab is to recreate an actuating Iron Man MK5 helmet using 3D-printed components, servos, a PCA9685 servo driver, and an Arduino Nano Every microcontroller.

This build also integrates an Adafruit Analog UV Light Sensor Breakout (GUVA-S12SD). The mechanical and wiring steps are based on the original creator’s instructions (Thingiverse MK5 Helmet), with additions noted where your UV sensor is integrated.

Electronics

1. Arduino Nano Every — 1
2. Adafruit PCA9685 PWM Driver — 1
3. SG90 9g micro servos — 8
4. Wing servos — 2
5. Battery pack / USB power bank — 1
6. Slide switches — 2
7. Limit switch — 1
8. LED eye panels — 1 pair
9. JST connector kit — 1 set
10. Wire (26AWG, multicolor)
11. Capacitors (per wiring guide)
12. USB angle adapters (L + R) — 2

Optional Component

1. Analog UV Light Sensor (GUVA-S12SD)

3D-Printed Parts

All STL files from the Thingiverse MK5 Helmet package. See Build Guide STL inventory table. mk5_BuildGuide. The filament used for this projects was Sunlu PLA 2.0 plus. The 3D printer used was the Bambu Labs X1 Carbon but any printer could be used to complete this project.

Hardware (Bolts)

From Build Guide:

1. M2×4mm — 24
2. M2×6mm — 22
3. M2×8mm — 25
4. M2×10mm — 2
5. M3×6mm — 6
6. M3×8mm — 40
7. M3×10mm — 4

Also reference this video for where to buy components - You Won't Believe This 10 Servo 3D Printed MK5 Iron Man Helmet!

Print all STL files provided in the MK5 Helmet package. Lay out prints and verify quantities match the Build Guide. Attached is the Bambu Studios project profile. It is currently set up to print on an Bambu Labs X1 carbon. All the components have been oriented to achieve the best quality and print setting have been changed to ensure ease of support removal

Arduino nano every and Motor Controller

For all electrical components follow the mk5_WiringGuide pdf. It provide detailed instructions on wire length and what pins need to be soldered.

UV Sensor Wiring

1. 3.3V → VCC
2. A0 → OUT
3. GND → GND

Follow the upload steps in the Wiring Guide. mk5_WiringGuide

1. Open the Arduino IDE
2. Plug in the Arduino Nano Every
3. Install Adafruit PWM Servo Driver library
4. Select:
5. Board: Arduino Nano Every
6. Port: The COM port associated with your Nano
7. Choose which code file to upload (see options below)
8. Click Upload

OPTION A — Original Helmet Code (No UV Sensor)

Choose this if you are building the helmet exactly as designed by the original creator and not using the UV light sensor.

OPTION B — Combined Helmet + UV Sensor Code (Your Modified Version)

Choose this if you installed the GUVA-S12SD UV Light Sensor.

This version handles:

1. All original helmet animations
2. UV voltage reading
3. UV index output to Serial Monitor

Optional: UV Sensor Test Code (Before Integration)

Used only to verify the UV sensor works before wiring it into the helmet circuit.

1. Power servos through PCA9685.
2. Run open/close cycle using button.
3. Verify eyes on D6.
4. Verify UV sensor prints changing voltage & UV index.

Follow Build Guide steps.

Includes dome assembly, brow articulation, nose, cheeks, eye panel installation, wire management, and final housing.

1. Verify full open/close sequence
2. Ensure no servos bind
3. Check UV readings one last time
4. Secure wires and battery

Conclusion

You successfully assembled a fully actuating MK5 Iron Man helmet with synced servos, controlled via PCA9685 and an Arduino Nano Every, including a functional UV light sensor.