I've created a custom mmWave presence sensor enclosure which utilizes an ESP32 and a LD2410C mmWave presence sensor. I wanted something that looked good enough to put around the house and was as small as possible given the parts I chose to use.

Speaking of parts, I chose the LD2410C mmWave sensor which can be found here:

https://www.aliexpress.us/item/3256805078957066.html?spm=a2g0o.order_list.order_list_main.130.48b818027qmcHW&gatewayAdapt=glo2usa

I went with a USB-C style ESP32 devkit-C board. I realize there are an seemingly endless selection of these boards, so if this project interest anyone, please shoot me a model of the ESP32 you are using and I can customize the enclosure for your board.

https://www.aliexpress.us/item/3256805785997962.html?spm=a2g0o.order_list.order_list_main.142.48b818027qmcHW&gatewayAdapt=glo2usa

I went through a few iterations of this enclosure in which I tested out various different features, including ruthex style inserts for screwing down the board and various levels of venting. I ultimately elected to remove the brass inserts because it proved difficult to get a hot iron in the box without melting the sides. In addition, these boards dont move around a lot once they are stationary anyway, so I designed in a little nub to hold the board in place.

To insert the ESP32 I recommend angling the board into the base piece to where the USB clears the slot first. Then, you should be able to drop the other end of the board into the base and clip it into the nubs on the opposite end of the USB slot.

The LD2410C should fit right into the lid. There is a cutout for the pins on the front of the board to fit. I have also designed in some gaps for heat to escape out of the lid piece for the LD2410C and out through the top vent holes. Once you (gently) press the LD2410C into place, you can snap the retaining clip over top to hold it. The retaining clip is designed to only touch parts of the LD2410C that do not have componenets, so does need to be oriented correctly, but that should be obvious.

I have also included an extended base version of the enclosure for those who may not want to solder and prefer dupont style wires. The extra depth of the extended base should allow enough space to clear the dupont connector heads. I personally chose to solder and heat shrink my wires, which you can see in the photos.

As mentioned above, if anyone likes this project and wants to tweak things for a particular board, please let me know.

I have intentionally avoided a detailed description of the electronics part of this project because that could be a whole blog, but if there are questions I will do my best to answer. I programmed the board using ESPHome through Home Assistant. I would be happy to share my code for the device.  If you are completely new to all of this, I found this writeup very useful.

https://smarthomescene.com/diy/diy-presence-sensor-with-hi-link-ld2410-and-esp32-for-home-assistant/