Solar Mesh Node (v4) - High-Latitude Triple-PV Repeater

This is a rugged, self-sustaining solar enclosure designed for long-term outdoor deployment. Originally developed to monitor a fleet of modified solar buoy repeaters, this v4 design is optimized for medium to high latitudes where winter sun is scarce. It features an integrated triple-panel array and a high-capacity battery bay to ensure your mesh node stays online year-round, even in shaded tree-canopy environments.Updates from V3 to V4 were focused on the RAK mini mounting points. The screw holes are now properly sized for the hardware included with the RAK mini to self-thread.

Key Features

• Triple PV Array: Houses 3x 5V 200mA PV modules. The geometry is optimized for winter sun inclination. Each module is 60x110 mm.
• Redundant Power: Designed for 2x 18650 Li-ion cells and a RAK Wireless WisBlock (RAK mini). Each lithium cell has its own BMS chip, then both are paralleled to be plugged into the RAK board.
• Weatherproofing: * Integrated drip edge on the base to shed water away from the SMA seal.
  • Deep 9mm thick top cap with a 5mm bored-through "curve hole" for hanging—no flimsy loops to snap off in the wind.
  • Optimized cap threads for a tight, mechanical fit.
• Circuit Protection: Space to include Schottky diodes on each PV module to minimize mismatch losses from partially shaded faces.

Recommended Print Settings

• Material: ASA is highly recommended for UV resistance and heat stability. 
• Walls/Infill: Use at least 3-4 walls for structural integrity, especially around the hanging cap and SMA pass-through.
• Supports: Minimal supports may be needed depending on your printer's bridging performance for the internal bays.

Assembly & Post-Processing

1. Waterproofing: It is recommended to use Marine Epoxy to pot the PV module pass-through holes.
2. SMA Connector: For a permanent seal, a small amount of acetone (if printing in ASA) or marine epoxy around the SMA connector base ensures a moisture-tight fit.
3. Hanging: The cap features a 5mm internal channel designed for heavy-duty kite line, paracord, or galvanized wire.

Credits & Inspiration

This design stands on the shoulders of giants. Special thanks to the following for their foundational work:

• Solar Node Instructable by histeve
• Cath’s Hanging Solar Node (BeCoolHoney-Bunny)
• The PeakMesh Altitude

Note: This is v4 of the design. It has been refined through community feedback to improve thread engagement, hanging strength, and moisture shedding.