Original Prusa XL side tables

[Thanks to download!  If anything below is unclear, please let me know.]

These side tables for the Original Prusa XL are ideal for those who feed filament directly from filament dryers.  The tables mount to the 30mm aluminum extrusions and do not interfere with the Original Prusa XL enclosure.  

There are two sizes: the larger version is 480x240mm, large enough for the Sunlu S4.  The smaller version is 360x240mm, plenty large enough for most 2 spool filament dryers.  Regarding the Sunlu S4, you will need to replace the power cord with a 90 degree version (search for right angle C7 power cord).

Details: 

The 480mm table is a three piece surface.  The front piece is cantilevered and supported by "hotdogs".  The hotdogs are 20mm hollow cylinders that run the entire length of the table.  The middle and rear sections are well supported by the shelf brackets.

The 360mm table is two pieces and is well-supported by the shelf brackets.  Assuming a typical filament dryer in which the feet are close to the shelf brackets, no extra support is required.  If most of the weight is centered between the shelf brackets, hotdogs need to be used.

Materials:

• 480mm table:

  • 254g of orange filament

  • 847 g of black filament

  • 6 sets of hardware: M4x12 + flat washer + split washer + extrusion nut

  • 4 M3 heat inserts and 4 M3-8 screws

  • 3 or 4 tie wraps

• 360mm table:

  • 192g of orange filament

  • 462 g of black filament

  • 4-6 sets of hardware: M4x12 + flat washer + split washer + extrusion nut

  • 2 sets of hardware: M3x16 + 2*flat washer + split washer + nut (or nylock nut without split washer)

  • 2 M3 heat inserts and 2 M3-8 screws

  • 2-4 tie wraps

Print notes: 

• In photos, black filament is Tinmorry PETG-CF.  Orange filament is Prusament PETG.

• Print the tables face down, with supports. (I didn't remove the support material in the hexagon pattern.)  Use 3-4 perimeters, gyroid infill.

• Shelf brackets: use 3 perimeters, gyroid infill.

• Hotdog: this is actually a hollow cylinder.  Print with 6 perimeters for max strength, gyroid infill.

• Joiner: 3 perimeters, gyroid infill.

Assembly:

• Prepare the shelf brackets with three sets of hardware.  The machine vibrates so split washers are mandatory.

  

• Attach the shelf brackets to the extrusions.  You will need a ball allen wrench, accessing the screw head from the left side of the bracket.  The bottom extrusion nut should go into the bottom horizontal extrusion.  Tighten the bottom extrusion nut first to ensure it's centered vertically.  Then tighten the upper two extrusion nuts.  You may need to slightly loosen & retighten the hardware to get the bracket perfectly straight.

  

• Assemble the table surface.  Install the heat inserts.  For the larger table, and optionally for the smaller table insert the hotdogs through the loops, then push the table pieces together with the joiners in the slots.  Use M3-8 flat head screws to secure the joiners.  If you don't use the hotdogs, you must add the M3 hardware at the edges (circled in red below).

  

• Place the table surface on the shelf brackets.  Place the dryer power cord if you want it to drop down between the table and the printer.  If you have the Original Prusa XL Enclosure, be sure the bellows handle is above the table.  Add three or four tie wraps.  With hotdogs, the tie wraps go around the hotdogs and through the perforations in the shelf brackets (green arrows below).  Without hotdogs, tie wrap through the hotdog loops to the shelf bracket perforations. 

  

• Because of the height of the filament dryers (esp. Sunlu S4), I had to move my filament sensors from the vertical extrusion to the horizontal extrusion just above.  Fortunately the wires had the extra couple centimeters available.  I'll be looking for a more permanent solution....