Simple PTFE stop for Prusa XL for flex bypass of side sensors

Much simpler alternative to magnet-based upgrades for the Prusa XL side filament sensors.
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updated February 7, 2025

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The stock Prusa XL side filament sensors require quite a bit of force to get the filament through which is fine for rigid filaments, but pretty much rules out softer TPU/flex filaments. There are several designs available here which upgrade these side filament sensors to use magnets and greatly reduce the insertion force, but another option is turning off the side filament sensor and just running the filament into the PTFE tube, but the tube works better if it has some form of a stop - that's what this is, just a stop for the reverse Bowden tube on the XL that makes it easy to feed the flex filament into the PTFE tube while bypassing the side filament sensor.

Prints quickly with no supports needed. I used Prusament PETG in Prusa Orange, of course. 0.2mm SPEED settings. Mounts with an M5 screw which works well with my 3030 T-nut.

Remember that the PTFE inserts into the side filament sensors with a locking collet so you need to press the collar in before removing the PTFE tube. No collet is needed for my design, it should press in without much resistance and then the tension in the filament will keep it in place. 

Just remember to go into the settings and disable the associated side filament sensor.

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