BLE Mesh Sensor Node
Multi-sensor environmental node with 24-month battery life and BLE Mesh 1.1.
- Stack
- nRF52840 · BLE Mesh 1.1 · Zephyr · 4-layer PCB
- Role
- Schematic, PCB, firmware, mechanical
- Outcome
- Shipped 5,000 units. 24-month battery life on a single CR2477.
Challenge
The brief.
Client needed dense BLE Mesh coverage in a steel-shelved warehouse with sub-µA sleep current. Off-the-shelf modules wouldn't make the certification budget.
Approach
How we built it.
Custom nRF52840 module with optimized antenna matching network, low-leakage DC/DC converter, and aggressive sleep-mode firmware. Mesh model written from scratch in Zephyr.
Result
What shipped.
Passed FCC + CE on first submission. 24-month field life confirmed at 6-month checkpoint.
More work
Other recent case studies.
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