The Prusa XL 3D Printer: Everything You Need to Know

The Prusa XL is an upcoming large-format 3D printer by the popular company Prusa Research. As anticipation builds for its release, what do we know so far about the specs, features, and performance of the Prusa XL? This guide takes an in-depth early look.

Overview of the Prusa XL

The Prusa XL represents Prusa’s first foray into the world of industrial-sized 3D printing. It’s their largest and most advanced printer yet, building on the reputation of the smaller Original Prusa i3 MK3S.

Some key facts about the Prusa XL:

• Build volume of 250 x 250 x 300 mm (9.8 x 9.8 x 11.8 in)
• Intended for reliable 24/7 operation and high-volume printing
• Next generation magnetic heatbed with PEI spring steel sheet
• Triple XY stage with linear rails and belts for stability
• Custom 32-bit Prusa mainboard and Raspberry Pi 4 controller
• Self-leveling probes and fully networked for remote control
• Expected pricing from $2000 to $4000+ depending on features

This gives a taste of how the XL aims for much greater scale and capability versus existing Prusa printers. But there are still many unknowns before the official launch.

What’s the Difference Between the Prusa XL Variants?

Prusa has teased multiple versions of the Prusa XL coming at different price points:

Prusa XL– The base model focused on core performance with upgraded motion and heatbed systems. Expected as the most affordable model around $2000-$3000.

Prusa XLastic– Adds a toolchanger system for swapping between multiple filament nozzles and tools. Allows multi-material and multi-color printing. Will cost more than the base XL model.

Prusa Super XL– The high-end configuration featuring full enclosure, camera monitoring and other advanced functions. Aimed at maximizing print quality and automation. Likely $4000+.

The unique toolchanger concept helps the XL achieve capabilities beyond normal Cartesian printers. But expect to pay more for the additional flexibility as you move up the tiers.

What Features Does the Prusa XL Include?

Here are some of the key features we know about the Prusa XL design so far:

• Huge build volume – At 250mm cubed, the XL dwarfs most consumer printers for massive prints.
• Triple x-axis – Three parallel x-axis frames share the print forces for increased stability.
• Self-leveling probe – Automatic mesh bed leveling before each print via inductive probe.
• Multi-material options – Toolchanger and MMU enable printing with multiple colors or filament types.
• Next-gen heatbed – Silicone heater and spring steel PEI sheet allow quick heating to 110°C.
• Filament runout – Sensors pause printing if filament runs out or breaks.
• Raspberry Pi controller – More powerful than 8-bit boards for advanced functionality.
• Connectivity – Ethernet, WiFi, and camera allow monitoring and controlling prints remotely.

These technologies aim to take Prusa to the next level in terms of both print quality and ease of use.

How Does the Prusa XL Toolchanger Work?

One unique aspect of the XL series is the toolchanger mechanism for swapping print heads automatically. Here’s an overview of how it works:

The toolchanger housing sits above the hotend carriage and can accommodate 4 tools plus the main nozzle. Tools are stored in a rotating carousel.

To swap tools, the print head moves to the dock. The carousel rotates to align the desired tool with the docking bay. The dock moves vertically to engage and swap tools.

This allows mixing and matching nozzles of different sizes and specialized tools like a laser engraver or scraper. Up to 5 tools can be configured as needed for the print.

The XLastic model is expected to include 2 extruders plus a selection of secondary tools. The possibilities are expansive for multi-process printing with the docking system.

What Print Volume Does the Prusa XL Have?

The advertised maximum print dimensions of the Prusa XL are:

• X axis (width): 250mm
• Y axis (depth): 250mm
• Z axis (height): 300mm

This gives a total build volume of 250mm x 250mm x 300mm, or 18,750 cubic centimeters.

In comparison, the print volume of other popular large-format printers includes:

• Creality CR-30 (300 x 300 x 400 mm) – 36,000 cc
• Artillery Sidewinder X2 (300 x 300 x 400 mm) – 36,000 cc
• Creality Ender 6 (220 x 220 x 300 mm) – 14,520 cc
• Prusa i3 MK3S (250 x 210 x 200 mm) – 10,500 cc

So among consumer models, the Prusa XL print capacity sits between mid-size printers like the Ender 6 and ultra-large options like the CR-30.

The 250 x 250 x 300 mm build is a versatile balance of scale and footprint. But Creality’s tall-frame designs eke out even more volume for extremely big prints.

What Print Speed Can the Prusa XL Achieve?

Specific print speed details have not been released yet by Prusa. However, some educated guesses can be made based on the hardware and intended uses.

Given its industrial focus and sturdy linear rail construction, the Prusa XL will likely print faster than the 100-200 mm/s speeds of the i3 MK3. But not as fast as core-XY printers over 300 mm/s.

A realistic estimate would be 150-250 mm/s print speeds. Moving multiple heavy x-axis stages limits the maximum velocity somewhat, but still faster than Prusa’s smaller printers.

Higher accelerations of 1000+ mm/s2 should also allow for crisp and clean prints even at high speeds. And the 750W power supply has plenty of headroom to heat faster.

For prototyping, speeds slower than 150 mm/s will yield the best surface quality. But the Prusa XL aims for 24/7 production where higher speeds are valuable.

How Much Filament Can the Prusa XL Use?

Given the large 250mm x 300mm print height, the Prusa XL will chew through filament quickly on bigger jobs.

A 0.4mm nozzle at 0.2 layer height has a volume per meter of filament of approximately:

250 mm x 300 mm x 0.2 mm = 15,000 mm3 = 15 cm3

So printing a full-height object would take:

300 mm height / 0.2 mm layer height = 1500 layers 1500 layers x 15 cm3 per layer = 22,500 cm3 volume

With a 1.75mm filament diameter:

22,500 cm3 / (π * (1.75/2)2 mm2 * 1 m / 1000 mm ) = 6,600 m length

In other words, a full build volume single print could take 6600 meters of filament – over 4 miles!

Now realistically, you’ll do prints far smaller than that maximum cubic volume. But it demonstrates the large appetite of the XL, necessitating multiple spools.

Expect to go through 0.5-2kg of filament for typical large prints – significantly more than a MK3S.

What Nozzle Sizes Can Be Used?

While a 0.4mm nozzle is standard, the toolchanger system allows easily swapping nozzles of different diameters.

Prusa has stated nozzles from 0.25mm to 1mm will be supported. Even wider nozzles may be possible for rough prototyping or specialty materials.

The independent toolheads with their own hotends minimize the need for nozzles to match. This gives flexibility to pick nozzle sizes tailored to each part of your print.

Small nozzles like 0.25mm can achieve fine details and textures where needed. While a 0.8mm+ nozzle speeds up larger layers.

Customers will likely have a selection of nozzle sizes to choose from. Each can be swapped in minutes before a print via the automatic toolchanger.

What Materials Can the Prusa XL Print With?

Prusa Research has built a reputation for printing with a wide range of both common and exotic filaments. So users expect the XL to be a similarly versatile material platform.

We can safely assume the Prusa XL will support all the standard materials printable on a MK3S:

• PLA
• PETG
• ASA
• ABS
• Nylon (with an enclosure)
• Flexible/TPU
• Composites like wood, metal, carbon fiber

The hotend redesign will likely use a bi-metal heat break to allow printing at 300C+ for high temp filaments. And the multi-extruder XLastic model provides perfect flexibility for dissolving supports.

Plus custom nozzle X upgrades planned for abrasives like carbon and metal composites. Beyond the basic plastics, the sky is the limit for materials on the modular XL.

What Software and Connectivity Will it Use?

Prusa has built their own custom 32-bit mainboard and electronics to power the XL. This provides native integration with their PrusaSlicer software plus the broader community options:

• PrusaSlicer – Prusa’s own slicer optimized for their printers. Will likely see XL-specific profiles.
• 3rd party slicers – Should also be compatible with alternatives like Cura, Simplify3D, and IdeaMaker.
• G-code monitoring – Integrated sensors can pause prints and notify users of errors.
• Camera monitoring – View print status remotely via webcam.
• Network connectivity – Wifi and Ethernet allow controlling the device over a network.
• Firmware Updates – Easily upgrade firmware over-the-air to enhance features.

These smarter printer capabilities will help users manage and monitor XL print jobs for maximum productivity.

How Easy is the Prusa XL to Assemble?

As a kit 3D printer, owners will need to fully assemble the Prusa XL upon delivery. However, given its large form factor and precision required, the kit process will be more intensive than the typical i3.

Prusa discusses multi-day guided assembly involving:

• Structural frame and motion systems
• Running axis wiring and cable chains
• Mounting printbed and inductive sensor
• Installing hotend extruder assemblies
• Attaching electronics enclosures and power supply
• Loading and calibrating firmware
• Test printing and tuning

Compared to the 8-10 hour i3 kit, builders should block off a full weekend for tackling the XL step-by-step build. Some mechanical aptitude and patience will be beneficial.

But the guided process aims to make it feasible for motivated customers rather than only factory trained experts.

Is the Prusa XL Worth the Price and Wait?

With the many advanced features and large scale, the Prusa XL commands a premium price tag, likely from $2000 to $4000 depending on the configuration.

Is the XL worth the higher cost and wait for delivery versus more affordable options already available? That depends on your specific needs:

Pros

• Larger print capacity than most common printers
• More reliable and consistent than DIY options
• Automated multi-material capabilities
• Advanced networking and monitoring functions
• Robust Prusa ecosystem and support

Cons

• Much higher cost than mid-size printers
• Overkill features and size if not utilizing full volume
• Other large printers available now with similar volumes

The price reflects the XL’s industrial design goals. For businesses and serious users needing maximum scale and automation, the cost may be easily justified by productivity gains.

But hobbyists may be better served by a mid-range printer and upgrading later once XL prices mature after early adopters.

Should You Wait for the Prusa XL or Buy Now?

The Prusa XL likely won’t be released fully until late 2023 or 2024. If you need an affordable large-format printer today, some good alternatives exist:

• Creality CR-30 (300x300x400mm) – More volume for less cost
• Artillery Sidewinder X2 (300x300x400mm) – Proven quality Cartesian printer
• Creality Ender 6 (220x220x300mm) – CoreXY speed in smaller size
• Tronxy X5SA Pro (300x300x400mm) – Budget DIY large printer

However, waiting could make sense if you want specific Prusa capabilities:

• Multi-material upgrades only available for XL currently
• Prusa reliability and support preferred
• Leading print quality and features out-the-box
• Maximizing build volume with 300mm height

There are always shiny new printers on the horizon. Determine if your needs justify buying now or awaiting future Prusa XL advancements.

Either way, the Prusa XL looks poised to shake up large-format printing once launched. Keep an eye on this upcoming printer heavyweight.

Conclusion

The Prusa XL represents an ambitious next-generation printer pushing the boundaries of desktop fabrication. Early info and teasers indicate impressive performance and usability improvements over previous Prusa machines.

If the high price tag doesn’t deter you when pre-orders open later this year, the Prusa XL offers a professionally-supported workhorse that can take your large prints to the next level.

Of course, details may change as release gets closer. But the core focus on maximizing reliability and quality at higher build volumes will make this a highly anticipated 3D printer launch.