The trickiest piece here looks like the electronics bridge. The projector's pinout does not match the Pi's, and instead of giving up, the maker designed a custom green adapter board that converts the BeagleBone Black pinout to something the Raspberry Pi Zero can work with. Solving that mismatch with a purpose-built PCB is the kind of unglamorous work that makes the rest of the build possible, and it seems handled cleanly.
The assembly itself is tidy. A Pi Zero sits inside the projector enclosure, which is a DLP LightCrafter Display 2000 EVM, with a small cooling fan inside the housing managing heat. A wooden dowel forms the structural arm between the mask and the electronics, and a grey adjustable welder's head strap holds the whole thing on the head, joined to the mask with threaded barrel bolts. Foam padding inside the mask adds comfort. Power comes from a black Anker 10000mAh pack strapped to the arm with zip ties, connected through a USB cable with a right-angle barrel jack. The mask was printed on an Ender 3, the full assembly was modelled in Fusion 360, and the visuals were prepared in After Effects and Photoshop.
Some details really stand out. The framebuffer dimensions were swapped in config.txt to get portrait orientation, and the video content is masked to fit the exact shape of the low poly faceplate. Since the projector sits at an angle below the face, the images come out skewed, and the content accounts for that. The results look fun: a human face, a Guy Fawkes mask, surveillance footage and scrolling green code, with text like NO AVOIDING IT appearing on the surface.
One trade-off is worth flagging. The mask blocks most of the projector light, but seeing out is still hard. A short throw projector is the hoped-for upgrade once small ones actually exist. In my view the 10000mAh battery is a sensible pick, since at a 400mA draw it should run for roughly 17.5 hours.
Project by SeanHodgins. Watch it on their YouTube channel: