Meshy_Wio Tracker L1 E-ink 3D Printed case

🧭 Project Overview

The Seeed Wio Tracker L1 E-ink is a powerful and versatile tracker built for off-grid communication, location sharing, and group coordination.

For this project, I designed a custom rugged case that makes the device more practical, durable, and stylish, especially for outdoor and tactical use.

This case transforms the tracker into a reliable companion for:

• 🚨 Emergency communication when mobile networks are down
• 🏕️ Group coordination during trekking, camping, or exploration
• 🎯 Staying connected with friends at events or remote areas where signals are weak

💡 Motivation

Seeed Studio hosted a competition to design cases for their Meshtastic devices. While researching existing entries, I found most of them were plain box-style enclosures—functional, but not visually exciting.

Since Meshtastic devices are used by tech-savvy adventurers (what I like to call cool nerds 😄), I wanted to create something that stands out — a case that’s both aesthetic and practical, with a rugged, tactical vibe perfect for outdoor use.

🔷 Project Name

I named the project MESHY, inspired by the mesh-based communication that powers Meshtastic devices.
The name represents the spirit of the device — smart, connected, and built for exploration.

Design Jo urney

Designing MESHY was a process of creativity, learning, and constant improvement.
Here’s how it evolved — from early sketches to final 3D prints.

✏️ Initial 2D Sketch

The journey began with a pencil sketch to visualize the initial concept. At first, I planned for a plastic body with TPU sides, but realized that combining two materials would complicate the process. I switched to a single-material design, focusing on simplicity and strength.

Early sketches looked like basic rectangular boxes, but as I iterated, the design became more aesthetic and functional.
Since the E-ink version of the device had extra space inside, I had the flexibility to shape the body beyond a simple box.

In my initial drawing, I hadn’t decided where to split the two halves of the case. This caused issues later since components like the hook, antenna, and GPS module were positioned near the center. I had to work around this problem during the CAD stage, which taught me an important lesson:

💡 Decide critical design splits early! It saves a lot of time and effort later in CAD.

3D CAD Modeling

For 3D modeling, I used Fusion 360.
The design started from the E-ink display, which acted as the base reference. All other parts were modeled around it and fully constrained to prevent alignment issues later.

I made the entire design parametric, so key dimensions could be easily updated without rebuilding the model — a time-saver for future modifications.

While designing, I had to split the main body into two parts for assembly. This turned out to be quite challenging since most of the key components — such as the hook, antenna, and GPS module — were located near the center. Because of this, I couldn’t make a simple, flat separation; instead, I had to create a non-linear cut, which can be clearly seen in the final model.

To join the two halves, I used small filament pieces as connectors. Both sides have precisely aligned holes where the filament slides in, locking the parts together. This solution is not only strong and lightweight, but also easy to replace if the filament ever gets damaged — a simple, practical approach that keeps the design repair-friendly and accessible.

During the CAD phase, I also planned a holder to make the device mountable and easy to carry.

Holder Design

I wanted a mountable holder that could clip onto belts, bags, or tactical straps and hold the device securely.
Instead of hinges or mechanical clips, I used a flexure-based snap-fit design — no moving parts, just clever geometry.

Highlights:

• Designed for 3D printing — strong, minimal, and efficient.
• Uses a snap-fit lock that keeps the device secure until intentionally removed.
• The snap slot is hidden in the side pattern for a clean look.

Parametric & Customizable Design

The case was designed to be parametric, so users can adapt it easily.
Customizable parameters include:

• Battery thickness – supports different capacities (default: 1000 mAh)
• Hook thickness – can be adjusted for extra strength
• Filament diameter – fine-tunes the locking system holes

Aesthetic Touches

The first version looked plain, so I added front and side patterns inspired by Protronics Power Bank designs.
These cutouts gave the case an industrial look and also cleverly hid the snap joints.

Design Time-Lapse

Here’s a short Fusion 360 time-lapse showing the full modeling process:

🖼️ Render

All renders were created in Blender — an incredible open-source tool.
Huge thanks to the Blender team and community for making such creative freedom possible! 🙌

🔸 Please take a look at all the renders — they showcase the customization potential and overall design beauty of MESHY!

The renders demonstrate how easily the design can be customized .

Here’s an exploded view showing all the printed parts. The body and buttons are printed in different colors, allowing endless personalization options.

Here are additional rendered images of the device, highlighting the elegance of the case and the effort that went into its design. Please take a moment to view all the images.

And this image showcases the individual parts of the final output.

🔁 Design Evolution

From the initial proposal to the final version, MESHY went through several refinements:

• Front & Side Patterns: Improved the industrial aesthetic and hid snap-fit joints.
• Fastening Method: Switched from screws to a snap-fit + filament lock, simplifying assembly.
• Form Factor: Made the overall design more compact, modern, and functional.

The early version felt bulky, but these updates made it lighter, easier to build, and far more visually appealing.

3D Pr inting Process

Before finalizing the print, I tested tolerances and fine-tuned hole sizes.

The body and joystick were printed at a 45° angle, which improved both strength and surface finish. Despite the angle, print time stayed the same — and when I showed it at my tinker space, everyone noticed how much smoother and more uniform it looked.

Print settings:

• Body & Joystick: 45° angle for better structure and finish
• Buttons & Hook: Printed flat with 100% infill for strength
• Supports: Used tree supports for efficient removal

Infill:

• Case → 20%
• Buttons/Joystick → 100%

The full print takes about 3 hours for the body and 30 minutes for the small parts — quick and efficient for such a rugged design

Design Iteration & Errors

Like most design journeys, MESHY went through multiple iterations to reach the final optimized version. Each iteration taught me something new.

In the early prototypes, I initially used screws to fasten the two halves of the case. However, this approach took up unnecessary space and made the product look less refined. I replaced it with a flexure mechanism, but the small snapping features occasionally broke under stress since the case was compact. To solve this, I introduced small filament pieces that connect both sides of the case. This turned out to be a simple, strong, and durable solution — one of the most effective changes in the design.

For the holder, I also went through a few iterations to get the perfect snap-in feel. The first version was too loose, so I shortened the length of the snapping feature. This adjustment gave me the tight, clicky, and satisfying fit I wanted.

Another small but crucial mistake was with the display orientation. Since I didn’t have the physical device during early modeling, I accidentally positioned it upside down, which caused issues with cable routing and required a longer FFC cable. I corrected this in the final version once I had the actual device in hand.

Throughout the process, I also ran small test prints for features like filament fitment. Testing played a big role in refining the final design and ensuring everything aligned perfectly in the prototype stage.

🧩 Assembly Gu ide

Assembling MESHY is straightforward and satisfying.

• Fix the hook to the front shell.
• Insert filament pieces into their holes.
• Place buttons into slots (temporarily hold with masking tape).
• Mount antenna with its screw, and secure GPS using foam tape.
• Solder battery leads to the main board.
• Connect GPS and antenna to the board.
• Attach battery behind the board using tape and screw the board in.
• Connect ribbon cable, slot in the E-ink display, and tape lightly.
• Close the case and remove temporary tape — done! 🎉

Internal Layout:

• Antenna: Mounted via built-in screw
• GPS Module: Foam-taped in its slot
• Main Board: Fixed with M2 screws
• Battery: Attached behind the board
• Display: Slotted and taped gently

💰Bill of Materials (BOM)

+--------------------------------------+-------+-----------+
| Item                                 | Qty   | Price     |
+--------------------------------------+-------+-----------+
| Wio Tracker L1 E-ink                 | 1     | $31.90    |
| WLY394058 3.7V 1000mAh 1S LiPo Bat.  | 1     | $4.20     |
| M2 screws                            | 4     | $0.80     |
| PLA filament                         | 40g   | $0.50     |
+--------------------------------------+-------+-----------+
| Total                                |       | $37.40    |
+--------------------------------------+-------+-----------+

🏁 Conclusion & Future Improvements

MESHY turned out to be exactly what I envisioned — a rugged, stylish, and practical case that’s both compact and easy to assemble. The parametric design allows customization, while the ability to change colors and patterns makes each unit unique.

It solves the challenge of carrying Meshtastic devices safely and conveniently by offering a secure, belt-mountable holder that locks the tracker in place. The case also encourages creative personalization — users can print buttons in fluorescent or glow-in-the-dark materials, experiment with textures, or modify the dimensions directly in CAD.

For the future, I plan to:

• Improve seam quality using resin or SLA printing
• Increase wall thickness for extra strength
• Develop a waterproof version for outdoor durability
  Explore a metallic version for a premium finish

MESHY isn’t just a case — it’s a reflection of creativity, precision, and the maker spirit. 💪

Gallery

Image showing the device being held in hand.

This image shows the device attached to a bag.

3D-printed holder that attaches to a belt, bag, or tactical gear.

Video demonstrating the device snapping onto the holder.

Different cases that I have created.

Meshy in its home ground.