Start by popping the popcorn. In a large pot, heat a small amount of oil over medium heat, add the popcorn kernels, cover, and shake until popping slows. Once ready, transfer the popcorn to a large mixing bowl.
In a medium saucepan over medium heat, combine the granulated sugar, butter, and light corn syrup. Cook while stirring occasionally until the mixture comes to a boil and the sugar dissolves completely.
Allow the mixture to boil for about 4-5 minutes without stirring until it reaches a golden caramel color. Remove from heat and carefully stir in the baking soda, vanilla extract, and a pinch of salt. The mixture will bubble up, so be cautious.
Immediately pour the hot caramel over the popped popcorn. Using a spatula or wooden spoon, gently fold the caramel into the popcorn until evenly coated.
Add in the mini chocolate chips and crushed nuts. Mix well to distribute them throughout the popcorn.
Allow the mixture to cool for a few minutes until it's manageable to touch. Grease your hands with butter or wear cooking gloves. Grab small handfuls of the popcorn mixture and shape them into balls, squeezing tightly as you form them.
Place the popcorn balls on a parchment-lined baking sheet and let them cool completely to set.
Notes
For best results, use fresh popcorn and let the caramel cool slightly before shaping.