Mesh or star topology in wireless networks – which is better for industrial IoT?

In industrial IoT, the way devices connect can make or break your system’s reliability and efficiency. Two common wireless topologies – mesh and star – offer different strengths. Understanding their trade-offs is key to building a robust and future-ready industrial network.

What you need to know about star topology?

In a star topology, all end devices (nodes) communicate directly with a single central coordinator – usually a gateway or base station. This hub handles all traffic between the nodes and the external system, such as a cloud platform or local server.

Key features:

• Single point of communication
• Simple setup and maintenance
• Low latency in ideal radio conditions

However, if the central coordinator fails, the entire network goes down. In large areas or environments with heavy interference, nodes far from the hub may experience dropped connections or total communication loss.

What is a mesh topology?

A mesh topology enables devices to communicate with each other, forming a network where data can travel through multiple hops. There is no strict dependency on a central point for communication. Instead, the network dynamically builds and maintains routes.

Key features:

• Decentralized, redundant communication
• Self-healing capabilities – the network adapts when a node fails
• Strong coverage in large or complex environments

Mesh topologies are ideal for scenarios where robustness and flexibility are critical, especially in industrial settings filled with obstructions like machinery, concrete, or metal structures.

Industrial use case comparison

1. Reliability

• Star: Network failure if the central gateway is lost.
• Mesh: Redundant paths allow the system to keep working even when some devices go offline.

2. Scalability

• Star: Limited by the capacity of the central device.
• Mesh: Can support hundreds or thousands of nodes through distributed routing.

3. Range and coverage

• Star: Dependent on direct line-of-sight to the central point.
• Mesh: Expands naturally with each new device, allowing for extensive multi-hop coverage.

4. Maintenance and complexity

• Star: Easier to configure initially, but harder to maintain as the network grows.
• Mesh: Requires more setup, but simplifies long-term management in dynamic or mobile environments.

5. Latency and throughput

• Star: Fast for short-range applications with minimal interference.
• Mesh: Slightly higher latency due to multiple hops, but more stable overall in challenging conditions.

When to use mesh in industry

Mesh networks offer distinct advantages in environments such as:

• Factories with moving equipment and physical obstacles
• Mines, tunnels, and multi-level warehouses
• Smart city systems involving sensors spread across districts
• Energy infrastructure like grids, substations, and pipelines

Protocols such as 6TiSCH (based on IEEE 802.15.4 TSCH) are tailored for deterministic, time-synchronized mesh communication. Industrial solutions like embeNET are built on these technologies, offering robust, interference-resistant wireless networking even under the harshest conditions.

When star might be enough

Star topologies can still be a practical choice for:

• Small-scale deployments with a clear line of sight
• Static environments where devices rarely move
• Low-node networks like single-room monitoring or short-range asset tracking

For example, a small cold storage room with just a few fixed sensors might run efficiently on a star network without the added complexity of mesh.

But in most industrial environments, mesh remains the more reliable and scalable option – especially where downtime or coverage gaps are not acceptable.

Final thoughts

The decision between mesh and star topology depends on your use case, environmental conditions, and growth plans. If you’re working with large, dynamic or mission-critical systems, mesh networking provides the resilience, coverage and scalability that modern industry requires.

For complex industrial environments, technologies like embeNET offer proven mesh capabilities that scale with your needs – even under the most demanding conditions.