Prusa XL Top filament frame [update 8-9-2025]

UPDATE August 9 2025

Added a new version of the filament guide. This version is angled upwards 30 degrees on the back to keep more clearance for the bowden tubes
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Intro:

I like my Prusa XL a lot but the side back entries for the filaments is just not great imho. So I created a top frame.

Advantages:

1. Filament bowden tube reduced to 65cm (instead of somewhat 130cm)
2. Easy access to filament insert openings
3. Reduced width of the printer (no more spools on the 2 sides)
4. Easy mounting/removing of filament spools which hang conveniently next to one another above the printer

Description:

The frame is connected to the 2 top 30x30 frame parts of the printer.

A plate going from left to right has a hook from left to right to hook up 5 filament spool holders.

The spool holders have bearings for smooth rotation of the filament spools. Furthermore the spool holder axel is only held on one side for easy removal and placement of the filament spools. Also the holders have a grip so one can easily pick up the filament holder.

Below the wide hook with filament holders are 5 arms through which the filaments can be pushed from front to back. Way more accessible than the original filament entries.

I choose not to use the side filament sensors, just the ones in the tools. That means the bowden tubes can be way shorter, about half of the original. From the 5 new entry points the bowden tubes can go directly to the tools.

Additional you need rather some hardware like:

For the spool holders:

M8 hex bolts, preferably 85mm long

M8 washers (small size)

M8 nuts

10 bearings 22mm x 8mm x 7mm

For the frame:

2x M8 thread,about 55cm long

4x M8 nuts

Rather some different M3 bolts sizes 20mm to about 30mm

5 Bowden tubes (I like 2.5mm inner diameter) 2.5x4 65cm long . Also, you could remove the original tubes and cut off 65cm to use with the new frame.

5x Fest coupling PC4-M6

8x M3 T-nuts for the 30x30 profiles

Printing:

All parts are in one 3MF file. All parts that need to be printed are arranged over 9 print bed layouts. Each bed needs to be printed once (succesfully) for all parts.

Update: 5 parts for inserting filament have a new model. These are in a separate bed layout. The original (less good) version is still in the large 3MF file containing 9 bed layouts

Bed 1 and 2: 111m each, 222m total

Bed 3 and 4: 70m each, 140m total

Bed 5 and 6: 103m each, 206m total

Bed 7: 256m

Bed 8:  242m

Bed 9: 184m

Total: 1250m

Disclaimer:

Some photos added to this model are from concept models.

First I had the filament entry above the filament spools, but didn't like it so moved below the spools. This results in more easy access. Also even shorter bowden tubes.

Also the first filament spools holders had 2 arms and had to be taken apart to change filament spools. Now, the one sided version is wat more convenient to work with.

Then there was a model which did not have the grip for easy grabbing the spool holders.

Lastly, the 3D impression does not have the bowden tubes connected to the frame!

I would like to thank Surfalex2000 for creating a rather good 3D model of the XL. His model is included in the 3D assembly.