[ACOS] MeshPack Pro L1 for Meshtastic

MeshPack Pro

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 (coming soon), 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 weather-resistant, impact-resistant shell. The electronics mount securely inside with standard hardware, and antennas can be SMA for a compact build or N-Type for maximum performance and durability. 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.

3D Printing

Start by 3D-printing the required components, files are available on my Printables Project Page

• Center case (SMA or N)
• Front case (E-Ink or OLED)
• Display support (for E-Ink)
• Rear case
• Front bumper (rugged or slim)
• Rear bumper (rugged or slim)
• Power switch
• Reset Switch
• USB cover
• Button (Standard or Tall)
• Joystick (Standard or Tall)
• Button bracket

Material suggestions:

PLA+ PETG or ASA for rigid case parts

TPU for bumpers (for shock absorption) you can print them in rigid materials if desired

Resin or high-resolution PLA for button and joystick, standard materials will also be fine

Assembly Instructions

1. Prepare the Front Assembly

Position the front face down

If using E-Ink, place the E-Ink display in the location with the flex cable in the notch

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

Optional Tall controls might be useful for the rugged bumper

NOTE: Test install the joystick on the L1 before this step to ensure it fits, it's should fit snugly but not require too much force to install, if it's hard to put on, either scale up in the slicer, or let me know and I will provide a larger file

If using E-Ink, carefully install the E-Ink support on the E-Ink display

Place the bracket over the joystick and button and secure with two M2 screws, this will also hold the E-Ink support in place

Install the power switch and reset button, be careful how you hold the front until the L1 board is in place because they can fall out, optionally place two 10mm lengths of translucent 1.75mm filament in the LED slots to act as light guides

NOTE: If using E-Ink, connect the ribbon cable for the display before the next step

Position the Wio Tracker L1 board first ensuring the power switch properly slots into the 3d printed power switch cover

NOTE: Tilt the board down to carefully connect the joystick, you may need to carefully wiggle it from the front while applying gentle pressure on both sides, also be careful to ensure the screws from the bracket aren't touching the board

When the board is fully in place, secure it with 4 M2 screws

If you’re using an optional Grove module:

Place the accessory in the reserved space inside the case, secure it with 2 M2 screws, plug it into the Grove port on the L1

NOTE: At this point, nothing should be loose, and you should inspect everything to ensure it is properly aligned and that all controls move properly and don't bind

Flip the assembly over and install the front bumper, there are options for standard (rugged) or slim, and OLED or E-Ink

It will require slight pressure to push over the lip of the front and then should stay in place

2. Prepare the Center Assembly

Insert and secure the SMA connector (optional N-Type) into the center case

Use double sided tape or similar to secure the GPS antenna and install the USB cover, you may need to do a little sanding and sliding the cover back and forth a bit to ensure a good fit. It should be possible to move without binding but still stay in place even if you bump the case

3. Join the Front and Center Assemblies

Carefully connect the LoRa and GPS antenna leads to the Wio Tracker L1 board and align the front case to the center case

NOTE: Very carefully inspect the antenna connectors and the grove connection if used, to ensure that nothing is pinched between the case parts and that nothing is stretch or bent too much

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

NOTE: Check again at this step to ensure the USB cover slides properly and doesn't bind up, it may take multiple uses to get it to move smoothly

4. Prepare the Rear Assembly

Place the selected bumper on the rear and ensure it is fully clipped over the edges of the rear part

Flip it over and place the battery using double sided tape or similar

NOTE: Before connecting the battery ensure that the power switch is in the off position, especially if the antenna is not installed, this is to ensure there is no risk of transmitting without an antenna, which may damage the transmitter circuit

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

Install the antenna

5. Power Up, Test and Support

Switch on the device

Flash the latest firmware following the instructions at flasher.meshtastic.org

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

Setup the device using the instructions at meshtastic.org/docs/configuration

If you need further help, join the Meshtastic Discord Server

If you want to contact me, you can message me here, or use any of my official links, Discord is best. Alley Cat Official Links

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 that fit flush together to ensure a tight fit and correct tolerance.
• Don’t over-tighten 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 (coming soon).
• 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.
• Weather resistance vs. waterproof: The enclosure is "weather-resistant" but not submersible. The idea is that it will not be as likely to be damaged if it accidentally exposed to limited moisture or dust. It is not designed to be left out in the rain. For extra weather resistance, add rubber o-rings 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 battery connectors. Reversing leads will damage the board or the battery.
• Test before final assembly: Power on the L1 with antennas and battery connected before beginning assembly. Catching issues early saves you from redoing 16+ screws.

Future Updates

• Swappable battery packs: Li-Po and Li-Ion cell swappable packs that will not require tools and will have magnetic battery connections.
• Fully customizable: STEP files for all parts will be released soon, to allow easier modification and customization for endless possibilities.
• Assembly and modification video: Detailed video walking though every step of the assembly and setup process, as well as tutorials for customizing the files will be coming soon.