Prusa XL Active Heater Connection Port

This provides a fixed connection port for a 50mm hose into the lower area of a Prusa XL. I designed it to receive the heat output from an AC Infinity Thermoforge T3 heater (which I use to actively heat and automatically maintain my EnXlosure enclosed XL up to 60º C (2026-03-15: CORRECTION, I'm characterizing this differently now to say the max practical temperature this setup reaches is 55ºC), see my BarrittWorks YouTube video for a full introduction: 

I've included the STEP file so you can more easily modify this to fit to your printer (Prusa XL, or some other printer/enclosure). 

The vanes on the inside of the duct are an attempt to spread the exhaust evenly into the printer rather than dumping all the air at the end of the part where the 90º turn culminates. I want the air to turn into the printer along the entire length. Non-scientific tests (feeling with my hand) suggest the vanes are partially successful. They could certainly be removed if desired (another reason for the STEP).  

I printed this with organic supports that were hard to remove given the internal structures. Mine is currently PETG. I will switch it to a more heat-resistant material if that proves necessary. No special slicer settings. Printed with shrinkage-compensated filament profile. 

The inside of the model has a surface around it's inner circumference that is intended to allow an easy interference fit of an internal diffuser, or perhaps a plenum to help evenly distribute the inflow inside an enclosure. I designed a couple of these but then decided they were unnecessary. (This is perhaps born out by Prusa's new Core One L, which blows hot air broadly from below the heat plate, in effect somewhat as this does.) 

The mounting holes allow you to attach the port with T-nuts in the XL frame at the bottom and vertical extrusions (there are holes on all four sides for flexibility; I've attached mine on three sides). 

The original side panel for the EnXlosure needs to be shortened to make room. I choose to print a PETG panel (in black) working from the EnXlosure STEP files rather than cut down the original plexiglass panel. 

Here's a link to the enclosure I use, EnXlosure by Voxel3D_Nederland and the heater, AC Infinity Thermoforge T3 (non-affiliate links). I've adhered 3mm thick reflective insulation to the inside surfaces of the enclosure (with Elmers glue, literally what I normally use for a release agent on my print plates, works fine). 

Happy (actively heated) printing!