Have you ever dreamed of holding a piece of Iron Man’s genius in your own hands? Well, I did—and I turned that dream into reality with my very own Mark 50 Arc Reactor replica, built using 3D-printed parts and powered by customizable RGB LEDs. This isn't just a prop—it’s a glowing tribute to engineering, creativity, and innovation.

What sets this Arc Reactor apart is its smart lighting control. Using the WLED application, you can transform the reactor’s glow with a tap on your smartphone—cycling through dynamic visual effects, color patterns, and brightness levels, all in real-time. this project is designed to spark your imagination.

Step 1: Design & Print

To begin, I designed this iron man Arc reactor using Fusion 360. Since the design was two old so the link of fusion 360 is not available for modification. Although I'm providing the STL files for directly 3D Printing. The files are listed below:

• 1x Iron Man Based.stl
• 1x Iron Man Middle.stl
• 1x Iron Man Top.stl

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Step 2: RGB Strip Assembly

I began by carefully measuring and cutting the LED strip to fit snugly inside the reactor’s inner frame. The strip I used came with a pre-applied adhesive backing, so I simply peeled off the protective layer and pressed it firmly into place along the inner edge.

Once the strip was in place, I soldered the three key connections: 5V (power), GND (ground), and Data In. It's important to ensure the data flow direction is correct—the arrow on the strip should point away from the microcontroller input. A reversed connection could prevent the lights from responding.

Step 3: Microcontroller Selection

While a standard ESP32 would have done the job just fine, I chose the Beetle ESP32 for a specific reason: its ultra-compact size combined with high performance. In a project where space is limited and aesthetics matter, the Beetle ESP32 was the perfect fit. It packs the full capabilities of the regular ESP32—Wi-Fi, Bluetooth, and plenty of GPIO pins—into a tiny form factor, making it ideal for embedding into tight enclosures like this one. This microcontroller is responsible for controlling the WS2812B LED strip using the WLED firmware, which allows real-time lighting effects via a smartphone.

Step 4: Connection

You can follow the above circuit diagram to make the connection, however I choose GPIO 2 of DFRobot ESP32 for Connecting Din Pin of Ws2812b led Strip. In the above circuit diagram you can see some safety comments like resistor and capacitor, you can connect if you want otherwise the ESP32 can even handle smoothly.

Connection of WS2812B RGB led Strip With DFRobot ESP32

• WS2812B Strip VCC Pin To DFRobot ESP32 VCC Pin
• WS2812B Strip GND Pin To DFRobot ESP32 GND Pin
• WS2812B Strip DIN Pin To DFRobot ESP32 D2 Pin

Connection of 5V DC Jack with DFRobot ESP32

• 5v DC Jack Postive (+) Pin To DFRobot ESP32 VCC Pin
• 5v DC Jack Negative (-) Pin To DFRobot ESP32 GND Pin

Step 5: Uploading Firmware

Since I’ve already explained the complete WELDER firmware upload process in a previous article and detailed video tutorial, I won’t repeat the same steps here. If you haven’t seen it yet, I highly recommend checking it out before moving forward. Just follow the instructions in my earlier guide to flash WLED onto your DFRobot Beetle ESP32 using the official WLED web flasher.

Previous Project Link - Click Here

Step 6: DC Jack Assembly

I placed the DC jack into its designated slot in the back part of the reactor. It fit just right, and to keep it firmly in place, I used a small drop of super glue. This keeps the jack secure while still maintaining a clean and sleek look.

Once fixed, the jack connects directly to the 5V input of the LED strip and microcontroller, making it easy to power the reactor using any compatible adapter.

Step 7: Diffuser Assembly

Now when everything is done, it’s time to add the 3D-printed diffuser on top. This not only gives the Arc Reactor a clean and finished look, but also helps soften the light so it doesn’t appear too harsh or direct.

Once the diffuse place on its place, carefully apply a small amount of super glue, so that it can fit perfectly.

Step 8: Top Assembly

Now it’s time to complete the look by attaching the top 3D-printed panel of the Arc Reactor. I carefully aligned the top panel over the diffuser and pressed it into place. To make sure it stays secure, I added a small amount of super glue at the edges. Just a little is enough—too much can overflow and affect the finish.

Step 9: Testing

Once everything is done, I connected a 5V power adapter to the DC jack, and instantly, the reactor came to life with a beautiful glow. Using the WLED app, I explored a variety of lighting effects—from smooth breathing pulses to fast dynamic animations. Everything worked perfectly, with no flickering or connectivity issues.

The light was evenly diffused, the colors were vibrant, and the overall look was exactly what I envisioned—a miniature Arc Reactor glowing with energy and style.

Conclusion



In my conclusion this is one of the best DIY Arc Reactors, fully brought to life with stunning RGB effects, smart control through the WLED app, and a compact, high-performance core. From precise 3D printing to beautiful light diffusion and smooth wireless control, this build brings together both creativity and technology in a compact, eye-catching design.

If you enjoyed this build or found it inspiring, don’t forget to share it and support me. Let’s keep building cool things.