The Original Prusa XL has finally been revealed at Frankfurt, Germany’s Formnext 2021. Prusa Research has been teasing the CoreXY behemoth of a 3D printer since 2019, when it was announced in the Original Prusa Mini’s release blog.
The company has trickled out a few more details over the past two years, like the tool changer announced in Prusa’s November 2020 update, and just recently showcased a CoreXY printer based on the same technology as part of their Automated Farm System (AFS) featured in the ongoing Dubai Expo. But, this is the first in-depth info we’re seeing about the XL itself.
The 360 x 360 x 360 mm build-volume machine is now available for pre-order with a refundable deposit of $200 but is expected to start shipping in the loose timeframe of Q2/Q3 2022. The release lag is credited to difficulties sourcing parts for development, which is no surprise considering the ongoing global supply chain crisis – which could only be exacerbated by the extra CPU included in the “completely redesigned extruder” deemed the “Nextruder.”
You read that right, yes, an extra dedicated CPU inside the extruder. Forget tool changing for a second. As impressive as that is, the Nextruder has a lot of exciting new functionality to offer. First and foremost, Prusa has included a load cell sensor embedded within the heat sink that enables nozzle probing of the print surface. The company claims this system results in “an always-perfect first layer” due to the analog data readings it provides.
It seems a system like this was necessary, considering the amount of possible print head swapping going on with the XL. Not just in terms of automated tool changing (the tool changer mechanism is optional) since Prusa says the nozzle and entire print head assembly can be easily hot-swapped. Given that, it’s clearly crucial the printer has a highly accurate height calibration system to ensure it remains accurate with every swap.
And therein will likely be the biggest supply issue for Prusa: the number of print heads, and thereby CPUs (and their increasingly rare silicone) needed to meet demand. Though the most affordable ~$2000 Original Prusa XL includes just a single tool head and, presumably, no tool changer, the most premium version comes with a whopping five independent print heads for ~$3500.
Speaking of the tool changer, you’ll find more sensors here, including another load cell sensor to calibrate automatically changed print heads, while additional sensors ensure a successful swap. Prusa says it’s run “over half a million successful tool changes” using this technology “without a single hitch.”
Prusa noted the print head’s load cell sensor offers more benefits than just height calibration, too, such a nozzle jam detection. Seriously. The Prusa XL will now detect nozzle jams and pause your prints, giving you time to swap out print heads or clean the jam before continuing your print. The number of failed prints that this tech is likely to prevent is unfathomable, and that’s good news for both wallets and the environment.
The print head assembly includes a nozzle developed with E3D and a new hot end assembly designed to make swapping out anything in the printhead a breeze. Prusa didn’t specify whether the XL’s nozzles could be swapped toollessly, but the nature of the assembly and a mention of E3D’s Revo system (specifically to point out that it is different, mind you) suggests they probably can be.
There’s so much more we could discuss from Prusa’s detailed blog post accompanying the reveal, but one last thing we want to mention from the onset is the exciting segmented heatbed. To avoid waste and warping, Prusa has divided the XL’s heatbed into sixteen 90 x 90 mm segments that can be independently heated.
The divided heatbed means the build platform won’t need to heat up its entire surface for smaller parts, ensuring the print bed reaches temperature faster, uses less energy, and avoids potential warping when not in use. Apparently, this new heatbed is being integrated into other systems, such as the AFS printers, and allows for totally scalable build volumes. This component itself could be a DIYer’s dream.
The nature of this announcement necessitated a more detailed initial overview than we usually cover, but because we’re still wrapping our heads around all the new information Prusa has revealed, we’ll end it here for now. Subscribe to All3DP notifications to be in the loop when our more detailed review of the now-revealed Original Prusa XL goes live, or check out our blind speculation of what the XL might include from this past summer and laugh at our pitiful attempt to behold colossus.
License: The text of "Prusa Research Reveals Original Prusa XL, Opens Pre-Orders" by All3DP Pro is licensed under a Creative Commons Attribution 4.0 International License.
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