Magsafe Meshtastic Node

This is an enclosure to keep a RAK Wireless RAK19003 base and its RAK4630 LoRa module on the back of a Magsafe compatible phone for use with Meshtastic. It adds about 16mm to the total thickness of the phone. It can also be stuck to flat magnetic surfaces.

This project should not require soldering and costs around $50-80 depending on the parts you use and where you buy them from (I purchased all of mine from Amazon).

Fusion 360 and STEP files are available if you want to edit or remix this project.

Multi material is optional if you want the decorative design.

Note: I printed all of my parts on a Bambu Lab A1 Mini with cheap generic PLA filament. This design is dependent on the screws threading directly into the plastic. The sizing for the holes and fitment of parts may differ if you have a different setup.

IMPORTANT: If you are using the Muzi Works 17cm whip antenna that I'm using, make sure to put the washer that is included with the RAK kit under the nut. If tightened all the way like I thought that it was supposed to be, this specific antenna will short the signal pin to ground and cause big problems. I initially did not put the washer under it and couldn't pick up any nodes. After I installed the washer the signal pin was no longer shorted to ground and function was restored. The included stubby antenna in the kit does not have this issue.

Update 10/27: Revised SMA antenna hole to grip the hexagonal base instead of the small flat area on the threads to stay in place better while tightening. Enlarged USB-C port opening for better compatibility with larger USB-C connectors. 

Update 9/23: Added a version of the lid without the hole for the SMA antenna and loop for use with the RAK PCB antenna. Should be compatible with the regular base. Untested, print at your own risk.

Update 9/24: Updated base plate for better strength and compatibility with the magnet array listed. Added an optional magnet cover to cover up the sticky side of the magnets.

Supplies required:

• RAKwireless WisBlock Mini Meshtastic Starter Kit (with the included IPEX to SMA adapter cable)
  • The mini sized one with the RAK19003 base. The standard one will not fit.
  • Choose the one with the appropriate frequency for where you plan to use the node.
    • See: https://store.rakwireless.com/pages/lora-frequency-guide-by-region
  • I bought: https://www.amazon.com/dp/B0DFMMTQZM
• 104245 3.7v 2000mAh LiPo Battery with a JST PH2.0 connector (that is 10mm by 42mm by 45mm)
  • You can probably use a smaller one that fits within the dimensions listed but you will have less battery life.
  • I bought: www.amazon.com/dp/B0CNLNK5KQ
    • Update: If the linked battery is no longer available for some reason, you can use any other battery that fits in the dimensions stated.
    • Here is what it looked like:
• A LoRa antenna with a male SMA connector
  • Can really use any one that you like, just don't get like a giant one that is too heavy.
  • Get one with the appropriate frequency for where you plan to use the node.
  • I bought: www.amazon.com/dp/B0D7D6866W
• A Magsafe compatible magnet array
  • Preferably one with stronger magnets.
  • I bought: https://www.amazon.com/dp/B09FZ5Z7S4
  • The base plate has been updated to be compatible with these magnets.
• 6x M2*4 socket head hex screws
  • Probably not ideal to thread these into plastic, but they are what I had on hand and worked well enough for me
  • I used some from this set that I bought: https://www.amazon.com/dp/B0DCKCN2WM

Printing:

• Your printer's bed should be leveled or ideally have auto bed leveling. The base has a 1 layer thick part so that the magnets can attract the phone more firmly.
• The lid and the base should be printed with the insides facing up away from the build plate.
• I used 0.16mm layer height on the Lid to make the overhang a little nicer, but 0.2 should work fine.
• The base should be printed in 0.2mm layer height
• Supports are probably not required, but I put some in the overhang in the part above the usb-c port to make it look nicer.
• The decorative design on the lid is kind of hard to print because it has thin lines and such, but my A1 mini handled it acceptably.

Assembly:

1. Use a screwdriver or something to punch out sacrificial support layer in the screw holes on the base.
2. Make sure that the magnets are correctly oriented (They should attract the base to the phone and stick the Magsafe magnet array into the base.
3. Insert the reset switch button into the lid. (it is pretty small, use tweezers or something)
4. Install the Wisblock into the lid and screw it in with the screws included in the kit.
5. Insert the IPEX to SMA adapter into it's hole in the Lid and secure it with the included nut from the outside.
6. Connect the smaller IPEX end of the connector to the one on the Wisblock labled “LoRa".
7. Screw your antenna onto the SMA connector
8. IMPORTANT: Check the polarity of the battery connector! Some are wired up backwards which will destroy the Wisblock! Refer to this guide: store.rokland.com/blogs/news/rak-meshtastic-starter-kit-battery-polarity
   1. Mine was wired up backwards and I had to carefully push down the locking tabs in the connector with tweezers to swap them around. Be careful while doing this and don't short the battery.
9. Place the battery into its spot and secure it with either double sided tape under it or some kapton tape across the top.
10. Connect the included Bluetooth PCB antenna to the connector labled “Bluetooth” on the Wisblock and secure it to the flat part in the lid behind the battery. The cable can be run across the top of the battery.
11. BEFORE CONNECTING BATTERY: Ensure that the LoRa antenna is properly connected and that the IPEX connector is seated properly on the Wisblock. The radio chip may be damaged if it is powered on without its antenna.
12. Connect the battery to the battery connector on the Wisblock (It's the larger one on the side of the LoRa Antenna connector).
13. My battery was charged and the Wisblock was already flashed with Meshtastic from the factory so it started working immediately. You might have to charge yours with the usb-c cable and/or flash it with the Meshtastic firmware.
    1. I followed this guide to set it up with my phone: https://store.rokland.com/pages/quick-start-guide-rak-wireless-wisblock-meshtastic-starter-kit
14. If everything is in working order, screw the lid and the base together to finish the project.

Liked this design? Please consider giving me a tip so that I can make more nodes: ko-fi.com/jq910