Prusa XL official enclosure upgrade - Over the top feeding filament

With this upgrade you can feed filament over the top of your Prusa XL official enclosure.
1h 19m
2× print file
0.25 mm
0.15 mm
0.40 mm
21.00 g
17
29
5
666
updated December 9, 2024

Description

PDF

Intro:

With this mod you can feed filament over the top of the Prusa XL original enclosure without the need of drilling holes to the metal sheet. You have to drill the top acrylic plate which is replacable (https://www.prusa3d.com/product/top-panel/) and costs aprox. 12 euros.

You do not have to completely dismiss the existing stock side filament feeding system. For examle you can feed tools 1, 4 and 5 from the sides and tools 2 and 3 from above. However, when you feed the printer over the top, you should deactivade the side filament sensors (Settings → Filament Sensors → Side Filament Sensor "X").

In my setup i also use this amazing mod https://www.printables.com/model/718498-prusa-xl-soft-tpu-cable-clip-to-extruder-prusa-xl by @Bernd to control the filament inside the enclosure. The only diference is that i use 23.5 cm instead of 2 cm long PTFE tubes. One for each toolhead, begining from the extruder and extending 23.5 cm upwards.

You can see my mod in action here: 

Printing Instructions:

  • Open “As project”.
  • 3 perimeters.
  • 15% Gyroid infil.
  • Supports: None.
  • 0.25 mm layer height for the “Drill_Template” 3mf file.
  • 0.15 mm layer height for the “Over_The_Top_Feeder” 3mf file (print in place, Do NOT separate the half-balls from the main body).
  • Tested with 0.4mm nozzle and Prusament PETG.

How to install:

Before you procced, you should have in hand:

  • 4 x Flat head M3x8mm bolts.
  • 4 x M3 washers.
  • 4 x M3 nuts.
  • 5 pieces 10mm long and 4mm wide PTFE tube
  • one 4 mm drill bit.
  • one Step Drill bit (like this one).
  1. Remove the four upper plastic rivets of the top acrylic panel of the enclosure. 
  2. Install the “Drill_Template” on top of the top acrylic panel and securing it with 4 Flat head M3x8mm bolts, nuts and washers.
  3. Using the installed “Drill_Template” as a guide, drill 5 holes (one for each toolhead) using a 4mm drill bit.
  4. Remove the “Drill_Template” guide. Keep the 4 x M3x8mm bolts, nuts and spacers, you will need them later.
  5. Now, using a Step Drill bit (like this one) widen the 4mm το 18mm holes (or 11/16 if you are not familiar with the metric system).
  6. Cut 5 pieces 10mm long and 4mm wide PTFE tubes and press fit them to the “Over_The_Top_Feeder” half-ball holes.
  7. Install the “Over_The_Top_Feeder”  on top of the top acrylic panel and securing it with 4 Flat head M3x8 bolts, nuts and washers.
  8. Well done!

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