We modelled a geodesic dome in Blender, and found a continuous strip of triangles that doesn't intersect itself when laid out flat. The whole thing was designed to fit a Raspberry Pi Zero W, with room for powering it with a USB plug.

The circuit board was then designed from this shape, using KiCad. We also played with Eremex TopoR (topological autorouter) to get the shortest possible distance of traces conecting the LEDs.

It is only now that we realised that most fab houses charge for rectangular space used. Clearly our design is very inefficient in this regard, being full of empty, wasted space. This realisation occurred only AFTER we sent the armature for printing, so here is what it might have looked like: