SENA Cast Industrial Mesh and Bluetooth Headset with headband -28dB NNR

The Sena CAST-01 is a headband industrial headset combining hands-free Mesh Intercom communication with hearing protection for noisy working environments.

Headband version

Published earmuff ratings: NRR 28 dB (ANSI S3.19-1974), SNR 34 dB (EN 352-1:2020), SLC80 33 dB (AS/NZS 1270).

• Over-the-head earmuff design
• Weight: 474 g
• Full-duplex hands-free communication
• Advanced Noise Control™ with boom microphone
• Ambient sound feature
• Bluetooth profiles: HSP, HFP, A2DP, AVRCP
• Up to 9 hours talk time with the included rechargeable battery
• USB-C charging: 2.5 hours full charge; 20-minute quick charge provides up to 3 hours Mesh Intercom
• AAA battery backup supported
• Operating temperature: -20°C to +60°C
• Certified CE, FCC, IC, KC

Open Mesh or a closed group?

Open Mesh is a shared conversation for compatible users on the same Mesh version and channel. Group Mesh is a separate, membership-controlled conversation for up to 24 users. You switch between the two rather than hear both at once.

To create a CAST group, the intended users hold the Mesh Intercom button for five seconds to start grouping. Once the group is saved, a three-second hold switches between Open Mesh and Group Mesh, with a spoken confirmation. Without an existing group, the prompt is “No group available”.

Listen without transmitting

Microphone mute lets you remain in the Mesh conversation and listen without transmitting your microphone audio. This is different from switching Mesh Intercom off. The microphone is unmuted by default.

Using older Sena equipment

The current CAST manual describes switching from Mesh 3.0 to Mesh 2.0 in the Sena Industrial App to communicate with legacy Mesh 2.0 devices. Check the firmware and available settings on the actual units. A mixed CAST, EXPAND Mesh and MeshPort Blue team must use compatible firmware, a common Mesh version and the same Open Mesh channel. MeshPort Blue does not join Group Mesh.

Coverage and connections

Sena quotes up to 1.1 km in open space, extendable up to 4.4 km with at least six users positioned to provide intermediate connections. Extended network coverage is not the direct range between any two headsets. Buildings, terrain and gaps between users affect coverage.

CAST supports connections to compatible two-way radios. The manual describes radio audio overlay during Mesh communication; this is not simultaneous Open Mesh and Group Mesh monitoring, and does not by itself establish compatibility with a theatre or broadcast intercom.

Read our plain-English mesh intercom buying guide for help comparing standalone team communication with a wider production system.