Sena EXPAND Mesh Intercom Headset

The Sena EXPAND Mesh is a lightweight, 100 g headset for hands-free team communication without a central base station. Its low-profile neckband design allows surrounding sounds to remain audible; it is not a hearing-protection earmuff.

Mesh communication

Current Sena specifications list Mesh Intercom 3.0, six Open Mesh channels and up to 24 Group Mesh participants. Mesh 3.0 was added in firmware v1.1. Earlier documentation describes nine Open Mesh channels, so check the firmware and Mesh version on existing units before extending a team.

Shared channel or selected group?

Open Mesh is a shared conversation for compatible users on the same Mesh version and channel. Group Mesh is a closed conversation for selected members. EXPAND Mesh switches between these conversations rather than letting you hear both at once.

To create a group, two or more Open Mesh users hold their Mesh Intercom buttons for five seconds to start grouping. Once a group is established, a three-second hold switches between Open Mesh and the saved Group Mesh. A voice prompt announces “Open Mesh” or “Group Mesh”. The headset remembers the group, so you do not need to create it again each time. Without an established group, the prompt is “No group available”.

Listen without transmitting

Microphone mute lets you listen to the selected Mesh conversation without transmitting audio from your own microphone. This is different from switching Mesh Intercom off. The microphone is enabled by default.

For a mixed team with CAST and MeshPort Blue, use Open Mesh with compatible firmware, the same Mesh version and the same channel. MeshPort Blue cannot join Group Mesh. When adding EXPAND Mesh to an existing Sena system, check the existing units' firmware and Mesh version first.

Working range

Up to 400 metres in open terrain, extendable up to 1.6 km with six or more users positioned to provide intermediate links. Buildings, terrain and gaps between users affect coverage.

Features and specifications

• Bluetooth 5.2: HSP, HFP, A2DP and AVRCP
• HD speakers with Advanced Noise Control™
• Audio Multitasking™ for intercom and music
• Up to 10 hours talk time; approximately 3 hours charging
• Weight: 100 g
• Low-profile over-ear fit and neckband
• Sena app support for settings
• Operating temperature: -10°C to +55°C
• CE, FCC, IC and KC certification; 2-year warranty

A standalone team conversation is not automatically a connection into an existing theatre or broadcast intercom. Confirm any required interfaces before choosing equipment.

Read our plain-English mesh intercom guide for coverage, group conversations and production integration advice.