[ACOS] MeshPack Pro L1 for Meshtastic

MeshPack Pro

MeshPack Plus

How It All Started

The original MeshPack design began when I picked up a RAK WisMesh Pocket. It was a capable device, but the enclosure left a lot to be desired. Rather than settling for it, I started sketching my own case, something sturdier, more adaptable, and better suited for real-world use. That first experiment gradually evolved into a universal enclosure system that can be tailored to many different development boards. Along the way, I’ve been collaborating with a growing group of testers who are trying out different variations, and I’m even developing an open-source board to help others get started more easily. My goal is to release everything as open hardware, so anyone can build, customize, and expand on the design.

Why I Built This One

The [ACOS] MeshPack Pro L1 was born out of a gap I kept running into: IoT hardware is either fragile development boards that live on your desk or fully sealed commercial units you can’t customize. The Seeed Wio Tracker L1 is powerful, but by itself it isn’t built for fieldwork. I wanted an enclosure that could survive outdoor use, adapt to different needs, and still be easy to tinker with.

What It’s About

This project transforms the Wio Tracker L1 into a rugged, modular handheld that you can carry into the field. It’s not just a case; it’s a platform. The design features swappable battery packs, customizable bumpers, support for both SMA and N-type antenna connectors, and optional expansion space for Grove modules. Instead of locking you into one configuration, it gives you a durable foundation that you can adapt to different projects and environments.

How It Works

The MeshPack Pro L1 is built from a set of 3D-printed parts that form a water-resistant, impact-resistant shell. The electronics mount securely inside with standard hardware, and antennas can be connected internally for a compact build or externally for maximum performance. Power comes from a removable battery pack with magnetic connectors, making it easy to swap or upgrade without opening the main enclosure. TPU bumpers provide shock absorption, while the Grove port allows you to plug in optional sensors or accessories.

In practice, the enclosure turns a bare PCB into a versatile handheld tool. One day it can be a GPS logger for hiking; the next day it might be part of a LoRa mesh for environmental monitoring. The CAD files are included so you can remix bumpers, battery housings, or even redesign the entire shell to match your own requirements.

Assembly Instructions

1. Print the Enclosure Parts

Start by 3D-printing the required components:

• Center case
• Front case
• Display support (for eink)
• Rear case
• Battery case
• Front bumper
• Rear bumper
• Port/switch cover
• Button
• Joystick
• Button bracket

Material suggestions:

PLA+ PETG or ASA for rigid case parts

TPU for bumpers (for shock absorption)

Resin or high-resolution PLA for button and joystick

2. Assemble the Battery Pack

Install the magnetic battery connector in the battery housing.

Place the battery in position and secure it with the cover.

Close the battery case with screws.

(Tip: check polarity before sealing the cover to avoid headaches later.)

3. Prepare the Front Assembly

Place the printed button and joystick into their respective slots in the front case.

(Optional) Install a clear screen protector or shield.

Position the Wio Tracker L1 board and fasten it with four M2 screws.

4. Add Grove Expansion (Optional)

If you’re using a Grove module:

Place the accessory in the reserved space inside the case.

Plug it into the Grove port on the L1.

5. Prepare the Rear Assembly

Install the matching magnetic battery connector into the rear case.

Insert and secure the antenna connectors (LoRa and GPS) into the center case.

6. Join the Front and Center Sections

Carefully connect the LoRa and GPS antenna leads to the Wio Tracker L1 board.

Align the front case (with board installed) to the center case.

Position the front bumper.

Fasten with eight M2.5 screws to secure the front assembly.

7. Complete the Rear Assembly

Plug the main battery connector into the Wio Tracker L1.

Attach the rear case and align the rear bumper.

Fasten with eight M2.5 screws.

8. Attach the Battery Pack

Align the external battery pack with the magnetic connector on the rear case.

The pack will snap into place magnetically and with alignment tabs.

(Optional) Use two M2.5 screws to secure the pack for rugged conditions.

9. Power Up and Test

Switch on the device.

Confirm that the board powers up, the display is active, and controls are detected.

Run a quick GPS or LoRa test to ensure connections are solid.

Troubleshooting & Pro Tips

• Check clearances before final tightening: Do a dry fit of each section before driving in all the screws. This helps avoid misalignment with the antenna connectors or bumpers. Gently sand or file any areas than fit flush together to ensure a tight fit and correct tolerance.
• Don’t overtighten screws: M2 and M2.5 threads strip easily in printed plastic. Tighten until snug, not until you hear a crack. If you can, used heat set threaded inserts.
• Mind the antenna cables: When connecting the internal LoRa and GPS antennas, make sure the cables aren’t pinched between the case sections. A crimped cable = poor signal.
• Water resistance vs. waterproofing: The enclosure is splash-resistant but not submersible. For extra weatherproofing, add thin rubber gaskets or washers on the antenna connectors and controls.
• Filament matters: Use TPU for bumpers if possible, it absorbs impact better than rigid filaments. PLA is fine for prototyping, but ABS, ASA, or PETG will hold up better outdoors.
• Battery safety: Double-check polarity when installing magnetic connectors. Reversing leads will damage the board or the battery.
• Test before final assembly: Power on the L1 with antennas and battery connected before sealing the case. Catching issues early saves you from redoing 16+ screws.