Original Prusa Enclosure (OPE) Cutout Saver

I've seen a few folks out there that have mistakenly removed the cutout thinking it was necessary for the optional filtration system sold by Prusa. Since I needed to remove the cutout for another project I was working on (fume venting), I decided to find a way to put the cutout back. Thus, the “Cutout Saver” was born.

The print is two pieces. The front and back are very similar and it doesn't really matter which goes where. The main difference is that one piece has a hexagonal extrusion that extends into a corresponding groove on the opposite piece. Your hexagonal cutout will be sandwiched in between these two pieces, effectively putting it back where you found it. 

The tolerances are not super tight (somewhere around + or - .1 mm), so there's just a tiny bit of play, but I suggest taking a blade to remove the nubs left over from removing the cutout, to make it an easier fit. 

You can use screws, but the plastic rivets that come with the enclosure (there should be a few left over) will work perfectly.

I tied to make it as thin as I could get away with and still keep it somewhat rigid. So, that's why it's set at -.20mm QUALITY. That's the minimum print setting I'd recommend. Because it's so thin the infill setting doesn't really matter. I also suggest printing in PETG given the higher temps inside the enclosure. 

I printed this in black to make it easier to photograph, but a clear filament will make it blend in better.

To Install:

Place both pieces in place (one of the outside of the enclosure and one on the inside).

Put the rivets into the bottom holes.*

Slip the plexiglass cutout back in place.

Put in the top rivets.

*It's important to push the back piece against the plexiglass when putting in the rivets so that they go all the way through both pieces.

Hopefully this helps someone. If you have any suggestions to improve this, please let me know.

If you really appreciate my work, you can also donate to my PayPal filament fund:

Note: This print was created in Fusion 360 and sliced in PrusaSlicer 2.6.0. Although probably not necessary, the holes for the rivets were placed in the slicer software (not Fusion 360) as negative spaces so they can be moved, if needed to account for any potential distance variants from one enclosure to another. FD3 & 3MF files are included if you want to tinker with the model.