Part no: CAST-02


Part no: CAST-02
What is included

Built on Mesh-Only communication technology, Cast ensures seamless and reliable user connectivity. With an additional hour of talk time compared to previous models, it offers extended usage for uninterrupted conversations. Cast stands out with its durability and improved construction, providing a durable, long-lasting device. Moreover, its innovative design incorporates outer speakers that capture ambient noise, ensuring safety in high-traffic areas.

About MESH Technology

Mesh is designed to optimize and repair itself, constantly seeking the best connection and automatically establishing a new one when a device becomes disconnected. Two different Mesh modes are available in the Cast system: Open Mesh and Group Mesh. Open Mesh allows many users to connect within an effective range of 1.1 km (0.7 mi), providing a wide-reaching network. Group Mesh is designed for private sessions, accommodating up to 24 participants.

Clear Communication For Optimal Safety
Maintaining open communication lines in worksites is crucial for safety. Cast addresses these concerns by utilizing full-duplex technology, enabling hands-free communication. This system empowers workers to communicate effortlessly and keep their hands free of distractions while working. The Cast headset offers hearing protection and effective communication capabilities in noisy and bustling worksites. Two styles are available: over-the-head earmuffs with a noise reduction rating of 28 dB and integrated hardhat design with a rating of 23 dB. The headset prioritizes safety and comfort, featuring a hands-free intercom system and a user-friendly layout with three buttons for easy control.

Long Talk Time to Accomodate Big Days
The CAST's talk time when connected to Sena's proprietary Mesh network can reach up to 9h, powered by its supplied removeable lithium polymer battery. The battery is fully charged in only 2.5 hours using a USB type C port. Additional lithium polymer batteries are available for keeping on hand to swap in when charging is not convenient. Alternatively, the CAST can be powered by 3 x AAA batteries.*

*The talk time may vary from each battery manufacturer.

Hard Hat Mount

  • Headset main units (Hat adapters (type A) attached)
  • Microphone
  • Rubber Rings for Microphone Sponge
  • Microphone Sponges
  • Hard Hat Adapters (Type B)
  • USB Power & Data cable (USB Type C)
  • Rechargeable Battery
  • Dual Battery Charger


  • Headset main units (Hat adapters (type A) attached)
  • Microphone
  • Rubber Rings for Microphone Sponge
  • Microphone Sponges
  • USB Power & Data cable (USB Type C)
  • Rechargeable Battery
  • Dual Battery Charger

Product Focus

  • Mesh Networking

    Robust and reliable communication network.

  • Advanced Noise Control

    Reduces the effects of ambient noise during intercom conversations.

  • Radio Connectivity

    Connect to handheld two-way radios.

  • Attentuation 28 / 23 dB

    Will reduce ambient noise by 28 dB (over-the-head) and 23 dB (hard hat).

Rugged, proven performance

Learn how Sena can meet your communication needs.
Download the Application Data Sheet.

Download PDF

Technical Specifications



  • Headset: 136 mm x 200 mm x 102 mm (5.3 in x 7.8 x 4.0 in)
  • Speaker Driver Unit: 32 mm (1.3 in) - thickness 7.1 mm (0.3 in)
  • Boom Microphone: length - 70 mm (2.7 in)


  •  Over-the-Head: 474 g (16.7 oz)
  •  Hard Hat Mount: 492 g (17.3 oz)


  • Operating Temperature: -20°C ~ +60°C
  • Storage Temperature: 15°C ~ +60°C
  • Charging Temperature: 0˚C – 45˚C


Over-the-Head Earmuff Type:

NRR (ANSI S3.19-1974, US) - 28 dB

SNR (EN 352-1:2020, EU) - 34 dB

SLC80 (AS/NZS 1270 Class 5, AUS/NZ) - 33 dB

Hard Hat Mount Earmuff Type:

NRR (ANSI S3.19-1974, US) - 23 dB

SNR (EN 352-1:2020, EU) - 30 dB

SLC80 (AS/NZS 1270 Class 5, AUS/NZ) - 30 dB


Noise Cancellation:

Advanced Noise Control™


Built-in SBC Codec


Mesh 2.0 Intercom™ Technology


  • Bluetooth 5.0
  • Headset Profile (HSP)
  • Hands-Free Profile (HFP)
  • Advanced Audio Distribution Profile (A2DP)
  • Audio Video Remote Control Profile (AVRCP)


Working Distance:

  • Up to 1.1 km (0.7 miles) in open space*
    *Can extend up to 4.4 km (2.8 miles) between a minimum of 6 users


Talk Time:

Up to 9 hours (with included Lithium Polymer rechargeable battery, talk time may vary if using 3 x AAA batteries)

Charging Time:

2.5 hours

Quick Charge:

20 minutes of charging equals 3 hours Mesh Intercom


Lithium Polymer Battery


1,100 mAh




Sena Device Manager

Instructions for Firmware Update

Step 1: Download

Download and install the Sena Device Manager on your computer.

Step 2: Update

Update the firmware of your Sena product with the Sena Device Manager.

MS Windows 32-Bit (Windows 7 or Later)

MS Windows 64-Bit (Windows 7 or Later)

Mac OSX (Mac OS 10.8 or later)

Firmware Histories

Cast v1.2 September 28, 2023

  • Added the options in the Sena Device Manager to enable / disable the pairing and connecting to a smartphone and use the built-in FM radio

Mobile App



Data Sheet


Certificate of Conformity