XL bellow enclosure

A Voron inspired enclosure that enclose up to top of X/Y frame. This encapsulate the head and reduce drag, and allow up to around 40 degrees inside the enclosure itself.

Modifications to original XL

• Removed the left/right side metal panels, and instead cover these areas with acrylics. This is for esthetics but also to reduce vibrations/noise that I was experiencing from these. (optional)
• Sealing up all edges and holes using these seals.
• Sealing up the hexagon back tool bay using these.

Polycarbonate/acrylic/plexiglass sheets needed, all with 3mm thickness

• 4x: 230x424x3mm for side panels. Only two needed if you decide not to remove the left/right side metal panels.
• 2x: 228x456x3mm for front doors.

Parts to print from Voron 2.4 repository

• https://github.com/VoronDesign/Voron-2/blob/Voron2.4/STLs/Panel_Mounting/Front_Doors/door_hinge_x6.stl, six of them.
• Panel mount: https://github.com/VoronDesign/Voron-2/blob/Voron2.4/STLs/Panel_Mounting/midspan_panel_clip_4mm_x7.stl, ~20 needed, but it depends on what else you have attached on your sides. Spool holders and filament sensors also serves as mounts.

Other hardware and parts needed

• 1mm foam tape for isolating inside of all panels. You need just over 7m in total. I bought two these from aliexpress (WxTxL 5mmx1mmx5m).
• 3M VHB tape, for mounting hinges and magnet holders to doors.
• M3 screws, 8mm and 10mm mostly, but some longer as well. Didn't remember what I used. Also some M3 washers.
• M3 T nuts. Like these or these.
• For fastening the vertical bar, you can either use a M5 screw and T-nut, or use a M3 screw with spacers (which I ended up doing). The hole in the bar is for a M5 nut.
• 12x M3 “voron style” heat inserts. I used these.
• 6x M5 heat inserts. I used these.
• Magnets for door: 10x5x2mm, eight of them. I have uploaded STEP files for parts needing magnets, so you can modify them for other magnets if needed.
• Magnets for top bar: 10x2 round, four of them.

Print and instructions

Printed on XL, using PETG at 0.2mm layer height using 0.4mm nozzle, structural profile. Minor support needed for top door bar. This one fit with some mm to spare diagonally on the XL.

Modularity

Some things might looks like there could have been one part instead of two, and this is true. I split up some parts to be able to iterate on smaller parts, instead of needing to re-print larger parts. The vertical bar and the vertical bar extrude can be one part instead of two.

Assembly instructions

To do, will follow up on this one! But in very short:

• Insert 3x M3 heat inserts on each side of each vertical bar.
• Mount vertical bar on left and right side. Orient the “opening”/"hollowing" towards the back of the printer, and the heat inserts outwards. We will mount the panels using these heat inserts.
• Insert 3x M3 heat inserts on the front of each "vertical bar extrude".
• Insert 3x M5 heat inserts of the back of each "vertical bar extrude".
• Mount left and right "vertical bar extrude", and screw them using M5 screws tight in the already mounted vertical bars. Keep in mind that the “vertical bar extrude” are different on left and right side ( the hinge holes differ in alignment).
• Mount lower bars, left and right.
• Install magnets to middle lower bar and install in middle.
• Install the 1mm foam strip on the the side panels.
• Mount panels on left and right side using the Voron panel clips.
• Mount 1mm foam strip on the front doors, but leave the edges that are going to end up in the middle of the printer, as these edges are not pushing up against anything. Also leave some opening for mounting magnet holders in top and bottom.
• Mount door hinges to “vertical bar extrude” together with the hinge spacers.
• Apply VHB to hinges.
• Hold up the front doors in the center and to the top, and close and press the hinges to tape them to the doors.
• Install magnets in top middle bar.
• Install top middle bar in top bar.
• Superglue magnets on left and right side on top middle bar.
• Install top middle bar.
• Install magnets top door magnet holders, and place them on top middle bar.
• Apply tape to top middle bar magnet holders.
• Close and push door against holders to attach them using the VHB tape.
• Repeat for lower magnets.

Probably forgot a bunch, but that should be it. Will update this text soon :).