MeshCard - Mobile Meshtastic Node
Compact and rugged Meshtastic node with aluminum case.
Overview
Recognizing a gap in the Meshtastic ecosystem for a truly compact, durable, and ready-to-use mobile node, I designed the MeshCard around a sleek 12mm-thick aluminum case with custom PCBA to eliminate loose wiring. Featuring the efficient RAK4631 (nRF52840 + SX1262), 1100mAh battery, optional GPS with power switch, and a high-gain 17cm antenna, it delivered multi-day runtime and excellent range in a durable, pocketable package.
I assembled, tested, and sold over 40 units while providing hands-on customer support and maintaining an optimized Meshtastic firmware build specifically for the MeshCard. The project validated a clear market need but also revealed the heavy time commitment of small-batch manufacturing and support, as well as the importance of pricing that properly reflects assembly labor.
Assembled MeshCards ready to ship.
Internal view of the MeshCard.
Custom PCB that I designed for the MeshCard.
Assembled board stackup.
Meshcard assembly in progress.
Accomplishments
- ✓Engineered a custom PCBA that minimizes wires/connectors to keep the device tight and reliable inside the aluminum enclosure.
- ✓Integrated Meshtastic firmware, antennas, and GPS control so the product works straight out of the box.
- ✓Delivered a weather-resistant enclosure with ABS end caps and managed batteries to handle extended field deployments.
- ✓Managed the procurement of all components.
Lessons Learned
- •High manufacturability is critical. The device was too complex and time-consuming to assemble.
- •Customer support is important and can be a lot of work. Customers are demanding.