Prusa Ultimate Gearbox (QoL Upgrades)

For CORE One XL users, please checkout @hnzxdv_720380's version here:

BACKGROUND

Haven't been the same ever since I used TPU for the first time. Been a bit paranoid about the incident; I can still smell the rubbery gears and melted loadcell, may you rest in peace.

Luckily (or not), dancan13f had a similar issue and made his own solution with his remix on the Prusa Nextruder Main Plate R2, and it's worked to give me peace of mind ever since. While this version does help to reduce the chances of filament jams, I still find myself having to open the idler to manually fix it.

Which is when I found KentO's MK4S Main Plate, which has an even narrower filament guide, which I found perfectly aligns the filament into the extruder. However, I noticed no one has remixed a version with any loadcell protection. So I spliced together the best of everything in order to minimize any new freak accidents that may occur in the future.

FEATURES

• Narrow Filament Guide

  • Aligns filament into nextruder nozzle entrance point.

  • Minimizes chances of nozzle clogs.

• Loadcell Heatsink Shell-Protection

  • Covers the loadcell heatsink so it's no longer openly exposed.

  • Minimizes chances of broken filaments or melted TPU from damaging wires under heatsink.

• Grooves along edges

  • Prevent gearbox from accidentally falling out during disassembly/maintenance.
    

REQUIREMENTS

1. Bogie Idler (from KentO's MK4S Bogie Idler & Main Plate Remix)
   

PRINT SETTINGS

Original 3MF files incluldes two parts, both of which are required and cannot be mixed with other variants (e.g. v2 and v3). Print-settings may not pre-configured by default, so double check the following:

• Infill: 15-20%

• Pattern: Grid or Gyroid

• Material:

  • PC-CF (Preferred)

  • PETG

    • If PC-CF is not available to you, this is an easily accessible solution.
      

HISTORY

• [01.21.26] Description updated

  • Added @hnzxdv_720380's model variant for Core One XL users.

  • Updated printing instructions for more details.

• [11.28.25] Version 3.1

  • Removed additional padding for better E3D nozzle fit.

• [11.27.25] Version 3.0

  • Re-added cutout from original model's design to fit with E3D type nozzles (e.g. obxidian).

    • If this causes issues with Prusa's stock nozzles, please try V2 instead.

  

• [11.25.25] Version 2.0

  • Spliced gearbox bedding from dancan13f's original design to the main plate.

  • No longer requires support to print.
    

    

• [11.24.25] Version 1.0

  • Initial splicing of main plate models.

  • Combines filament feed and loadcell heatsink cover.