4mm Thick Panels Remix for Prusa V2 Enclosure (for corrugated plastic panels)

3mm acrylic panels are a significant cost. It is cheaper to use coroplast (corrugated plastic) for some (or all!) of the panels of the enclosure. Coroplast also cuts easily and insulates very well. 

The only gotcha is that typical corrugated plastic is 4mm thick. The enclosure parts are designed for 3mm acrylic, so the solution was to remix the necessary parts to accept 4mm panels instead. The panel slots have been resized to 4.15-4.2mm wide while keeping the thickness of each wall constant at the original 2.0mm.

The upper channel pieces have been generously resized to 4.5mm channels to make fitment forgiving.

Suggestions: 

1. Replace all 3mm acrylic panels (including doors) with 4mm coroplast and make your own windows for visibility as needed…
2. OR keep the 3mm acrylic doors for visibility, and replace the other three side panels with coroplast. (The original 3mm slotted door hinge pieces are still compatible with the 4mm slot remixes.)

This remix contains only the parts from the Prusa Enclosure V2 (MMU2S) that hold the panels. Meaning: if you already own the parts from the V2 enclosure, but want to use 4mm thick coroplast instead of 3mm acrylic, print these parts and replace the originals with them.  

Thankfully the STP format CAD files were released for the original design, making this remix much easier!  I included my own STP file to make further mods easier.

One final note and perspective regarding fire risks of using Coroplast:

• It is NOT a bad fire hazard; it can catch fire, but it is more “melt” than “burn". It does not burn the way most plastics do.
• It does not ignite and go up the same way that wood or cardboard does.
• The IKEA LACK is itself made from wood and cardboard (just for perspective)

Modified slots for 3mm acrylic sheets to 4mm (to accommodate 4mm coroplast, for example)