Backbone Solar Repeater
Solar-powered Meshtastic repeater designed for long-term network stability
Overview
Designed, assembled, and sold solar-powered Meshtastic repeater nodes on Etsy under the product name "MeshBackbone." This project focused on creating a rugged, off-grid communication device for mesh networks, ideal for extreme weather, emergencies, or remote areas. The node integrates a custom PCB, high-efficiency solar charging, and durable components to ensure reliability.
Key innovations included oversized power systems for extended uptime, protective features like low-voltage cutoffs, and user-friendly mounting options. Sold multiple units, learned more about manufacturing and e-commerce.
Custom PCB I designed for the Backbone Solar Repeater. It integrated a battery tray, WisBlock, optional GPS, charge controller, solar input, and power switch
Top view of assembled Backbone PCBA. You can see the power switch, WisBlock, and battery tray.
Bottom view of assembled Backbone PCBA. You can see the solar input, charge controller, and GPS slot.
Model of the MeshBackbone enclosure. All parts were modeled in OnSahpe to ensure the off-the-shelf enclosure would fit the components.
Internal view of the MeshBackbone model assembly. You can see the battery tray and WisBlock.
Initial prototype unit used to validate major components and test an enclosure. In the end I switched to a slightly larger controller. This prototype continues to operate reliably in the field after 18 months of continuous operation.
Accomplishments
- ✓Custom PCB Design: Engineered a bespoke PCB for organized component integration (battery tray, GPS, charge controller, WisBlock), enhancing assembly and reliability.
- ✓Power System Reliability: Developed a setup with a 10W solar panel, 1A charger, and 37Wh battery capacity for over 30 days of backup, including low-voltage cutoff to protect against over-discharge.
- ✓Durability in Extremes: Housed in a waterproof ABS case with vent and sealed ports; proven in 80+ mph winds, hail, Hurricane Beryl, and other extreme weather in Texas, plus extreme cold temperatures in Wyoming and northern Idaho, with continuous operation.
- ✓Market and User Focus: Sold complete kits on Etsy with easy mounting (thumb-screw clamps), adjustable solar mount, and pre-flashed firmware, plus responsive customer support.
Lessons Learned
- •Battery Management in Cold: Learned that keeping discharge and charge rates of lithium-ion batteries low enough prevents damage in extreme cold temperatures, ensuring reliable performance in harsh winters.
- •Over-Engineering for Resilience: Sizing power components for worst-case scenarios highlighted the balance between cost and fail-safe performance in off-grid tech.
- •Iterative Hardware Design: PCB prototyping revealed integration challenges, teaching the value of rapid iterations to minimize errors and improve efficiency.
- •Environmental Adaptations: Adding vents and waterproofing showed how minor tweaks prevent long-term issues like moisture damage in outdoor applications.