Prusa XL enclosure below 120 €

Since I couldn't find a printer housing for the Prusa XL that met my requirements, I designed my own enclosure.

My requirements were:

• Cost-effective
• Minimal filament usage for printing the parts
• Free of shrinkage issues
• Free access to the print bed
• Frameless front panel
• Separately operable top and bottom doors
• The front flap should remain open due to its own weight and leave sufficient space above the printer housing
• Enough clearance for Prusa XL with 5 print heads
• Top-loading filament (especially for flexible filament)
• Dry box directly attached to the printer
• Standard spool holders should still be used
• A housing as airtight as possible
• temperature measurement in different areas
• Flexible for future accessories

General Information

To start building the XL printer housing, I recommend procuring the materials from the cost overview in advance.

1. Cost calculation and part list

2. Printed Parts

First, produce the 3D-printed components so that they can later be used as templates or for fine adjustments when cutting the housing parts from plywood.

2.1. Print instruction

• material: PETG
• material support: PLA (in case of 1 print head, PETG is also fine)
• supports: partly required
• layer height: 0,25mm or 0,32mm
• nozzle diameter: 0,4mm or 0,6mm
• brim: not required
• enclosure: not required

For T-Slot nut M4 see: https://www.printables.com/model/1113854-t-slot-nut-m4-with-tpu-spring-to-fix-parts-eg-to-a

2.2. Assembly instruction

1. remove support and deburr parts if needed 
2. connect parts with puzzle connection to one frame 

Note: Do not add hexagon nuts until plywood parts are not drilled, because printed part will be used as bore template.

3. Components to be manufactured

3.1. Plywood panels

Check whether the dimensions from the cost calculation fit your Prusa XL and your printed parts — if not, use your own measurements — then manufacture the housing parts from plywood.

3.1.1. Side Panel

3.1.2. Prepare lower side panel

To mount the side panel on the Prusa XL with minimal force, it is essential that the panel can move smoothly within the sliding rail. If this is not the case, I recommend sanding the side panel slightly until the desired clearance is achieved.

3.1.3. Top panel

If filament is to be loaded from above, I recommend adding slots to the top panel.

3.2. Plexiglass sheets

Check whether the dimensions from the cost calculation fit your Prusa XL and your printed parts — if not, use your own measurements.

3.2.1. Manufacture front door

Manufacture the parts according to the determined dimensions.

3.2.2. Manufacture top door

For an optimal transition between the angled and vertical panel, I recommend adjusting the edges to a miter cut using a router. Alternatively, this can also be done with a circular saw or plunge saw. After creating the miter cut, finish processing the parts to the exact dimensions.

4. Assembly instruction

4.1. Assemble enclosure

Connect the printed front frame to the plywood parts. To do this, align the parts against each other and drill the necessary holes in the plywood for M4 screws. After drilling, deburr and clean the parts. Before assembly, insert M4 nuts into the frame. Then, fasten the parts together using M4x16 screws. Finally, connect the plywood parts with the corner connector using the drilling template. Further details about corner connector see: https://www.printables.com/model/692380-corner-connector-to-build-up-eg-an-enclosure

Position of corner connector

4.2. Add bores for connector bracket and assemble to Prusa XL

To drill the holes for the connector bracket in the correct position, place the housing on the printer and position the connector bracket according to the dimensions in the illustration above. Then, drill the holes for M4 screws, deburr and clean the parts. Insert two T-slot nuts into the groove on the 3D printer, place M4 nuts into the connector bracket, and fasten the parts using M4x20 screws (top) and M4x25 screws (bottom) along with the spacer for the connector bracket onto the 3D printer.

4.3. Add lower side panels and sliding rail

Remove the dirt covers from the aluminum profile (top and bottom), insert the sliding rails, and slide the lower side panel into the sliding rails.

4.4. Add front panel

Add magnets (3 to each bore) to the front panel. Remove the dirt covers from the aluminum profile, insert the T-slot nut M4, and align its position with the holes of the front panel.  Then, slide the front panel against the side panel and secure it using M4 washers (3xd) and M4x12 screws.

Further details see: https://www.printables.com/model/1240032-front-panel-for-prusa-xl-enclosure

4.5. Add hinges for front door

Prepare hinge according https://www.printables.com/model/1175207-hinge-to-fix-a-door-to-eg-an-enclosure . 

Align the hinges, taking the thickness of the glass doors into account, and drill holes in the side panel for M3 screws. Then, secure the hinges using M3x16 screws, M3 washers (3xd), and M3 nuts.

4.6. Add front door to hinges

Align the front door, ensuring sufficient clearance between the two door wings, the front panel, and the printer housing. Then, drill holes for M3 screws and secure the front door using M3x16 screws, M3 washers (3xD), and M3 nuts so that the door can open and close freely.

4.7. Add door handle to front door

To attach the door handle, mark the center of the magnet on each door wing. For drilling the holes, I recommend disassembling the door. Drill a hole for a screw with a diameter of 4mm. Align the door handle vertically and secure it with Spax D4x16. Mark the second hole for the door handle and drill a hole for the second screw. Then, fasten the door handle with Spax D4x16 to each panel and mount the panels onto the side walls.

4.8. Add hinge for top door

Align the hinge components and insert the axle according to the marking below. Before mounting the lower right axle, ensure that the spring is installed. If the axles are difficult to install, widen the hole using a 2mm drill bit. Then, secure the hinge with the screws as shown in the image below.

4.9. Prepare front door

Check whether the panels have sufficient clearance from the frame and the lower doors. If the clearance is acceptable, mount the panels using the fixing brackets. Position the fixing brackets with an edge distance of 10–15mm from the panel, mark the drilling positions, and add the holes for M4 screws. Then, fasten the parts together using screws M4x16.

4.10. Add door handle

Mount the door handle as shown above using Spax 4x16 screws to the front door.

4.11. Add front door to Prusa XL

To execute this step, I recommend having a second person assist in holding the front door.

Align the top door with the frame and hinges, ensuring sufficient and even clearance on all sides. Mark the positions of the hinge drill holes and drill holes in the panel with a diameter suitable for 3mm screws. Then, mount the top door onto the hinges.

Congratulations! The printer housing is now complete. Enjoy printing and have fun with your projects! 

The displayed illustrations include additional equipment that can be accessed via the provided link https://www.printables.com/@H3dSprint/collections/2079967