3D Printed Mounts for LoRaWAN Sensors

Why 3D Print Mounts

Commercial weather station mounts cost 45-120 EUR and never fit exactly right. I design and 3D print custom mounts for 8-15 EUR in material. They're lighter, fit perfectly, and I can iterate the design in 6 hours instead of waiting 3 weeks for a supplier.

Common scenario: Need to mount anemometer on 32mm galvanized pipe at specific angle to clear solar panel. No commercial bracket exists for that combination. Design it in FreeCAD, print overnight in ASA plastic, install next day. Cost: ~11 EUR in material.

What I Design and Print

Sensor mounts:

• Weather station pole mounts (standard pipe sizes 25-60mm)
• Wall and ceiling brackets for indoor gateways
• Adjustable angle mounts for anemometers
• Multi-sensor platforms (combine temp/humidity/pressure in one housing)

Gateway enclosures:

• Custom-fitted cases for various gateway models (SenseCAP, Dragino, etc.)
• Waterproof outdoor housings with cable glands
• Battery compartments with ventilation
• Mounting brackets for specific installation scenarios

Cable management:

• Clips and guides for antenna cables
• Strain relief for outdoor installations
• Weatherproof cable entry/exit solutions

Material Selection

PLA: Indoor only for standard PLA. Cheap (20 EUR/kg), easy to print, but deforms in summer heat (>50°C). White PLA+ can stand the test of time in moderate climates where temperatures stay below 40°C. Use for prototyping or indoor brackets.

PETG: Best general-purpose outdoor material. Weather resistant, UV stable, strong. 25 EUR/kg typical. My go-to for most outdoor mounts.

ASA: Better UV resistance than PETG. Survives direct sunlight for years. 30 EUR/kg. Needs enclosed printer (fumes). Use for permanent outdoor installations.

TPU: Flexible rubber-like material. For gaskets, vibration dampening, protective bumpers. 35 EUR/kg. Slow to print but useful for specific applications.

ABS: Impact resistant, high temp tolerance. Warps easily during printing - PETG or ASA usually better choices. 22 EUR/kg.

Why It Makes Sense

Fast iteration: Design flaw discovered during test fit? Fix in CAD, print updated version overnight. Compare to ordering from supplier: 3-4 weeks lead time minimum.

Custom fit: Every installation is different. Pipe diameters, mounting angles, clearance requirements vary. 3D printing handles one-off requirements that injection molding can't justify.

Lightweight: Printed parts use 20-50% less material than machined alternatives. Matters for pole-mounted sensors where weight affects stability.

Complex geometry: Can print internal channels for cable routing, integrated cable clips, threaded inserts. Traditional manufacturing requires assembly of multiple parts.

Limitations

Not for everything: High mechanical stress applications need aluminum or steel. 3D printing is for brackets, housings, adapters - not structural components.

Surface finish: Layer lines visible. Not as smooth as injection molded parts. Functional vs cosmetic.

Production quantity: Makes sense for 1-100 units. Beyond that, injection molding becomes cheaper per unit.

UV degradation: Even ASA degrades eventually. Expect outdoor parts to last 3-5 years in direct sunlight. Then reprint.

Typical Projects

Weather station mounts: Standard utility poles (25-60mm diameter), building facades, agricultural infrastructure. Include cable routing channels and adjustable angles.

Gateway housings: Custom enclosures for various gateway models with antenna mounting, cable glands, ventilation slots. PETG or ASA depending on UV exposure.

Sensor packaging: Weatherproof housings for custom electronics. Design includes mounting brackets, battery access doors, cable entries.

Design Process

1. Spec gathering: Photos of installation site, measurements of mounting surface/pipe, clearance requirements, environmental conditions (UV exposure, temperature extremes).

2. CAD design: Model in FreeCAD (open source) or Fusion 360. Design for printability - avoid overhangs >45°, include print-in-place hinges where useful.

3. Test print: First version almost always needs tweaks. Test fit, identify issues, revise. Usually 2-3 iterations to get perfect fit.

4. Final production: Once design proven, print production quantities. Typical: 1-10 units per project.

5. Files delivered: You get STL files. Print yourself or use local print service. Design is yours to modify/reprint.

Print Settings That Matter

Layer height: 0.2mm standard. 0.3mm for faster rough parts. 0.1mm for fine details (rarely needed for mounts).

Infill: 20% sufficient for most brackets. 40% for high-stress applications. 100% infill rarely needed - wastes material and time.

Perimeters: 3-4 walls minimum for outdoor parts. Strength comes from perimeters more than infill.

Supports: Design to minimize support material. Wasted plastic and rough surface finish. Orient parts cleverly during slicing.

What I Provide

Services:

• Custom mount design based on your requirements
• Material selection guidance (PETG vs ASA vs...)
• Print settings optimization
• STL file delivery - yours to keep and reprint

You get:

• CAD files (STEP format - universal)
• STL files ready to print
• Print settings recommendations
• Installation tips

I don't print and ship physical parts. I design, you print locally. Keeps costs down, eliminates shipping delays.