Prusa Air 2 XL

by Miro87043, published

Prusa Air 2 XL by Miro87043 Oct 8, 2012




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I built the great Prusa Air 2 by Mecano and was thrilled with its performance. Especially the increased lateral stability added by the acrylic frame. However I like to use my dual fan mount x carriage and I lost over 25 mm of x travel. I also found it difficult to squeeze 100 mm of z travel out of it.

I made a few simple changes to allow full use of a 200 x 200 mm build platform and increased z travel to 150 mm. I also slightly increased the size of cross brace at the bottom to ensure no rigidity was lost.

Other subtle changes:
Changed the electronics holes to accommodate an Arduino Mega 2560 and Ramps 1.4. I also relocated the electronics up higher and depending on which side you put the pertaining panel the electronics can be mounted on the inside.

I took scotty1024's advice and made a laser cut y motor mount. I doubled the acrylic so its solid and slotted the holes to allow for tensioning and easy removal.

The slots are adjusted for acrylic that is 0.22" (5.6 mm) as that is what's available to me.

Also included is a acrylic base plate for use with Prusa 2 linear bearing mounts and 4 spacers for mounting electronics.

Update: I added spars to the sides that make the frame rock solid. I used acrylic weld to secure them.


Assembly is same as the original Prusa Air 2, but with updated rod lengths.

8mm smooth rod

5/16 (8 mm) threaded

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Hi, awesome improvements! 

Can you explain this base plate? You say it's for use with linear bearing mounts so it is obviously for the y-axis but why would you mount electronics there? There also seem to be a lot of holes for which I can not deduce a purpose in this base plate especially the 8mm hole on one side?

Hi, just wondering where you had the parts laser cut, as I canot find an appropriate size in Ponoko.thanks

I have access to a laser cutter at my local maker space. I could cut a set for you at $60 american plus shipping. Currently I only have white acrylic on hand though.

Hi I could explain where you have welded 2 side wings side reinforcements? You can add a photo? Thank you

I added a photo showing the spar detail on the right. It's the same on the left but must be added prior to the mounting the electronics.

is it possible to get the files in dwg or dxf format ?