Prusa Research Original Prusa XL User manual

3D PRINTING
HANDBOOK
FOR THE ORIGINAL PRUSA XL 3D PRINTER
ORIGINAL INSTRUCTIONS
ENG

Original Prusa XL: Official Instructions
Welcome to the world of 3D printing! Our 3D printers are designed to be as easy to use as
possible. Most situations will be covered by the intuitive menu on the screen, but for proper initial
setup and configuration, it is necessary to carefully study this manual. It won't take long and in a
few minutes, you will be printing!
Some texts may be accompanied by additional instructions in colored boxes - please pay
special attention to these texts.
Tips, advice or important information that will help you when working with the printer.
This part of the text is very important, please read it carefully! It depends on both the correct
operation of the printer and its safe operation.
This information applies to the Original Prusa XL 3D printer kit.
How to contact Prusa Research technical support:
First, check the last sections of this manual that deal with common problems, or go to
help.prusa3d.com where you will find a complete list of the most common problems and their
solutions. If your problem is not listed here, or the solution does not work, please send an email
to [email protected] and/or use our chat at prusa3d.com. Try to describe your problem as
accurately as possible - ideally include pictures or videos.
XL Official Instructions / User’s Manual v1.00 - February 12th, 2023
JOSEF PRUSA®, PRUSA RESEARCH®, PRUSA POLYMERS®, PRUSA ORANGE®, ORIGINAL PRUSA®, PRUSA 3D®, and
PRUSAMENT® are registered trademarks of Prusa Development a.s. used by Prusa Research a.s. under license from Prusa
Development a.s. | JOSEF PRUSA, ORIGINAL PRUSA, and PRUSAMENT are registered trademarks (or trademark applications) of
Prusa Development a.s. and are used by Prusa Research a.s. under license from Prusa Development a.s. in the following countries:
Australia, New Zealand, Israel, Mexico, South Korea, Turkey, Ukraine, Russia, Kazakhstan, Switzerland, China, Colombia,
Uzbekistan, Philippines and Norway. | All other company names and product names mentioned in this publication are trademarks
and registered trademarks of their respective companies.

About the Author
Josef Průša (*23. 2. 1990) developed an interest in 3D printing when he began studying at the
University of Economics in 2009 - it started off as a hobby, a new technology open to
modifications and improvements. The hobby quickly became his passion, and Josef became one
of the main developers of the international open-source (all works are freely available for any use)
RepRap project by Adrian Bowyer. Today, Prusa's design in various versions can be seen all over
the world; it is one of the most used printer designs. The goal is to increase public awareness of
3D printing technology.
All of Josef Průša's 3D printers are open-source. In the spirit of the RepRap project, you can use
your printer to produce parts for other 3D printers.
The Original Prusa product range is constantly being expanded with new models and
improvements. The main goal is to make 3D printing technology more understandable and easier
for ordinary users.
Josef Průša also holds workshops for the public, participates in professional conferences, and
promotes 3D printing. He has lectured at TEDx conferences in Prague and Vienna, at the World
Maker Faire in New York, at the Maker Faire in Rome, and at the Open Hardware Summit at MIT.
He has also taught the Arduino course at Charles University and was a lecturer at the Academy of
Arts, Architecture and Design in Prague.
In his own words, he envisions a not-so-distant future where 3D printers will be available in every
household. If anything is needed, you can easily print it out. The boundaries in this field are being
pushed every day… We are glad you are part of it!

Table of contents
1. Introduction 12 .............................................................................................................................................................
2. Original Prusa XL Overview and Glossary 13 .............................................................................................
2.1. Contents of the Package and Accessories 14 .....................................................................................
2.2. How to Move the Printer 15 ........................................................................................................................
2.3. Disconnecting the Power Source 15 ......................................................................................................
2.4. Error Screens 16 ..............................................................................................................................................
3. Your First Print 17 .......................................................................................................................................................
3.1. Basic controls 17 ..............................................................................................................................................
3.2. Selftest Calibration (Wizard) 18 ...............................................................................................................
3.3. Preparing Flexible Print Sheets 18 ..........................................................................................................
3.4. Running the Selftest 20 ...............................................................................................................................
3.5. Inserting filament 21 ......................................................................................................................................
3.6. Removing Filament 22 .................................................................................................................................
3.7. Starting the First Print 23 ...........................................................................................................................
3.8. Removing a Printed Object from the Print Sheet 24 ......................................................................
3.9. First Print Troubleshooting 25 ..................................................................................................................
3.9.1. First layer peeling off from the bed 25 ......................................................................................
3.9.2. Nozzle moves too high/low, or extrudes plastic outside the print area 25 .............
3.9.3. The nozzle does not start extruding, even after multiple attempts 25 ......................
3.9.4. After a few hours of printing, the nozzle stops extruding filament 25 ......................
3.10. Updating the Firmware 26 .......................................................................................................................
3.11. Sample Models 27 .........................................................................................................................................
3.12. Factory Reset 27 ............................................................................................................................................
4. Advanced User Guide 28 .......................................................................................................................................
4.1. Prusa Academy Courses 28 ........................................................................................................................
4.2. Network Connection 29 ...............................................................................................................................
4.3. Obtaining Printable Models 30 ................................................................................................................
4.4. Create Your Own Model 31 ........................................................................................................................
4.5. What is a G-code File? 31 ...........................................................................................................................
4.6. PrusaSlicer 32 ..................................................................................................................................................
4.7. PrusaSlicer Interface Explained 33 .........................................................................................................
4.7.1. Initial Setup and General Workflow 34 .....................................................................................
4.7.2. Using Supports 35 .............................................................................................................................
4.7.3. Speed vs Print Quality 36 ...............................................................................................................
4.7.4. Infill 37 .....................................................................................................................................................
4.7.5. Brim 37 ....................................................................................................................................................
4.7.6. Printing Objects Larger than the Print Volume 38 .............................................................
4.7.7. Printing Multicolored Objects (Single-Tool XL) 39 .............................................................
4.7.8. Slicing and Exporting 40 ................................................................................................................
4.8. Using Nozzles with Various Diameters 40 .........................................................................................
5. Material Guide 41 .......................................................................................................................................................
5.1. PLA 41 ...................................................................................................................................................................
5.2. PETG 42 ..............................................................................................................................................................
5.3. ASA (ABS) 43 ...................................................................................................................................................
5.4. PC (polycarbonate) and PC Blend 44 ....................................................................................................
5.5. PVB 45 .................................................................................................................................................................
5.6. Flexible Materials 46 .....................................................................................................................................
5.7. PA (Polyamide) / PA11CF 47 ......................................................................................................................
6. Regular Maintenance 48 .......................................................................................................................................
6.1. Flexible Print Sheets 48 ................................................................................................................................

6.1.1. Double-Sided TEXTURED Print Sheet 50 ..............................................................................
6.1.2. Double-Sided SMOOTH Print Sheet 50 .................................................................................
6.1.3. Double-Sided SATIN Print Sheet 51 .........................................................................................
6.1.4. Improving the Adhesion 51 .............................................................................................................
6.2. Keeping the Printer Clean 51 .....................................................................................................................
6.3. Linear Rails 51 ..................................................................................................................................................
6.4. Fans 51 .................................................................................................................................................................
6.5. Extruder Feeding Gear 52 ...........................................................................................................................
6.6. Extruder is Clogged or Jammed 52 ........................................................................................................
6.7. Cleaning the Nozzle 53 ................................................................................................................................
6.8. Troubleshooting Faulty Sensor Readings and Removing Errors 53 .......................................
6.9. Filament Sensors 53 .....................................................................................................................................
6.10. Flashing an Unofficial (Unsigned) Firmware: 54 ............................................................................
7. FAQ - Frequently Asked Questions and Basic Troubleshooting 55 ...............................................
7.1. Mesh Bed Leveling Fails 55 ........................................................................................................................
7.2. Printer Does Not Recognize the Inserted USB Drive 55 ...............................................................
7.3. Loose Belts 56 ..................................................................................................................................................
7.4. Homing Failed 56 ............................................................................................................................................
7.5. Heating Error 56 ..............................................................................................................................................
7.6. Fan Error 56 .......................................................................................................................................................
7.7. Reverting to an Older Firmware 56 .........................................................................................................
7.8. Nozzle Hitting the Sheet / Other Z-axis Issues 56 .........................................................................
8. Advanced Hardware Troubleshooting 57 ....................................................................................................
9. Troubleshooting Print Quality Issues 57 .......................................................................................................

6
Safety symbols and their meaning
Careful: strong magnetic fields
Careful: mechanical parts. Take care to avoid injury to hands when in close proximity to
the device with mechanical parts.
Further information regarding function and service can be found in this user (service)
manual or online at help.prusa3d.com.
Before any service intervention, it is necessary to first disconnect the 3D printer from the
power source and familiarize with the instructions.
Take extra care when handling or touching parts marked with this symbol, and avoid
further risks specified by specific symbols, such as hot surface hazards — burns may
occur.
Hot surface! The marked object may be hot and extra care should be taken when
touching it.
Unprotected moving mechanical parts can cause injuries, please take extra care.
Do not print directly on this surface.
High electrical currents are being switched on and off in the immediate proximity of parts
marked like this. Persons with an implanted cardiac stimulator or other devices for
controlling and regulating heart functions must take extra care and consult their doctor
before using the 3D printer.
This device is composed of components that must be disposed of in accordance with the
Directive on Waste Electrical and Electronic Equipment.

7
Product Information
Name: Original Prusa XL
Manufacturer: Prusa Research a.s., Partyzánská 188/7a, Holešovice, 170 00
Prague 7, Czech Republic
Contacts: Phone: [phone], e-mail: [email protected]
EEE category: 3 (IT / Telecommunications Equipment), device usage: indoor use
only
Power supply: 100-240 VAC, 10 A max., 50-60 Hz
Frequency band: 2400.0-2483.5 MHz
Maximum radio-frequency
output power: < 100 mW e.i.r.p.
WLAN standard: IEEE 802.11 b/g/n
Operating temperature
range: 18 °C (PLA)-38 °C
Maximum air humidity: 85%, non-condensing
Printer dimensions:
Width (incl. Wi-Fi antenna and filament side sensor): 580 mm
Depth: 700 mm
Height (incl. cables to extruder): 910 mm
Installed nozzle diameter: 0.6 mm
Weight (with packaging /
without packaging): 35.0 kg max. / 25.3 kg max. (without filament)
The product serial number can be found on the type label located on the back of the printer and
on the outer packaging.
This device is intended for use in indoor environments only and is protected against external
influences.
Operating conditions according to CEPT/ERC/REC 70-03

8
Declaration of Conformity
Manufacturer Prusa Research a.s. hereby declares that the product Original Prusa XL is in
compliance with Directive 2014/53/EU applicable in the European Union and the Statutory
Instruments 2017 No. 1206 applicable in the United Kingdom.
The full text of the Declaration of Conformity is available at: prusa.io/xl-documents.
Warranty
The Original Prusa XL 3D printer is covered by a 24-month warranty for end customers in the EU,
and a 12-month warranty for business customers and end customers in the rest of the world.
Consumables and parts subject to wear and tear are excluded from this warranty.
The warranty period starts on the day the customer receives the goods. The seller is not liable for
any damage caused by improper handling of the purchased product, or damage caused by
handling in violation of the information and recommendations given in the official manuals and
instructions. The warranty also expires in the event of unskilled interventions and the use of
unofficial hardware and software modifications.

9
Safety Instructions and Disclaimer
Acting in contravention of the information provided in the manual may lead to injury, poor print
results, or damage to the 3D printer. Make sure that everyone working with the printer is
familiarized with the content of this handbook and understands it correctly. As we cannot control
the conditions under which the Original Prusa XL printer is assembled, we do not assume any
responsibility and expressly disclaim any liability for losses, injuries, damages or expenses arising
out of or in connection with the assembly, handling, storage, use or disposal of the product. The
information in this manual is provided without any warranties, expressed or implied.
Be very careful when handling the 3D printer. It is an electrical device with moving and heated
parts.
Placement and Basic Use
Make sure that the printer is located and operated in a safe place to avoid potential risks.
This device is intended for indoor use only. Do not expose the device to water or snow. Contact
with water and other liquids may lead to damage to the electronics, short circuits, and other
types of damage. Always operate the printer in a dry environment.
Place the printer in a safe dry place on a horizontal and stable surface - e.g., a work table.
Around the printer should be at least 30 cm of space. If there are obstacles close to the
printer, it may affect its operation or cause excessive wear of the textile cable sleeves or even
the cables themselves. Worn cables can pose a risk (electric shock, fire).
Make sure that none of the exhausts/fans is blocked. The printer has a built-in fan speed
monitoring, but in some cases (incorrect assembly, damage to components, unofficial
firmware) the monitoring may not work correctly. Insufficient cooling can lead to overheating
and serious damage to the printer (risk of damage to electronics, fire).
Make sure that the printer is placed so that it cannot be toppled over or dropped to the
ground. If the printer has suffered physical damage, do not use it - damaged parts of the
printer may pose a safety risk.
The power cable must be placed so that it cannot be tripped over, stepped on, or otherwise
damaged. Place it on a stable, solid surface (e.g., a work desk). If the printer is damaged, stop
using the device, turn it off immediately and replace the cable. Damaged cables pose a safety
risk - there is a risk of electric shock or fire.
Do not leave the printer switched on without supervision! The printer has temperature
monitoring and a number of smart features for increased safety, but in the case of use
contrary to the instructions in this manual or failure of components, there is a risk of fire.
Never place anything into the printer under the heatbed - the heatbed is a moving part and
could crash into objects underneath it!

10
Electrical Safety
The printer should only be powered through a standard 230 VAC, 50 Hz or 110 VAC, 60 Hz
outlet. Never use alternative power sources as they can cause problems or damage the printer.
Do not use the printer if the power cord is damaged in any way – damaged cords can lead to
electric shock.
When disconnecting the power cord from the outlet, pull the plug, not the cord, to reduce the
risk of damaging the plug or outlet.
Never disassemble the power source of the printer as it contains no parts that can be repaired
by an untrained worker. Always take the printer to a qualified service technician for repairs.
Improper interventions in the power source may lead to damage to the printer and an
increased risk of electric shock.
The device is disconnected from the power supply by pulling out the plug. The electrical outlet
must be easily accessible.
The printer is equipped with a replaceable fuse located in the fuse holder near the connecting
connector of the power source and it protects the entire printer. Before replacing the fuse, switch
off the printer and disconnect the power supply by pulling out the power cord from the outlet.
Push the fuse holder out using a flat screwdriver, remove the fuse and insert a new one. Push the
fuse holder back in place. Always make sure the new fuse has the same value as stated on the
label (F10AH/250V). If the fuse blows repeatedly, contact the service.
Mechanical Risk
Moving mechanical parts of the printer can cause injury.
Never interfere with the inner components of the printer when it is connected to the power
supply or running – there is a risk of injury from mechanical parts or electric shock.
Prevent children from manipulating the printer without the supervision of an adult – even
when the printer is not printing.
Burn Risk
Do not touch heated parts of the printer – heatbed, print plate, and parts of the printhead.
There is a risk of burns.
Warning! During printing, parts of the printhead and the print plate can heat up to very high
temperatures! Do not touch them until the printing ends and the printer cools down –
otherwise, you may get burned.

11
Proper Use of Double-Sided Print Sheets
Each type of print sheet requires slightly different maintenance. Improper handling and use can
lead to damage to the print sheet, heatbed or other parts of the printer. Print sheets are
consumable and subject to wear.
The surface of the textured and satin print sheet must not be cleaned with acetone!
Please refer to the Flexible Print Sheets chapter for maintenance instructions.
To degrease the sheet’s surface, use highly concentrated isopropyl alcohol (90% or higher).
Do not use products that contain IPA as one of the components (e.g. hand sanitizers) - these
products usually contain other additives that may negatively affect the properties of the
printing plate.
Do not wash under running water - the sheet may start to rust.
Do not remove the PEI film from the plate surface.
Before printing, clean the sheet’s surface with an isopropyl alcohol-dampened wipe.
Printing sheets are held in place on the heated bed with strong magnets - be careful when
placing the sheet on the heatbed to avoid injury.
Do not slide the sheet when it is attached to the heatbed with magnets - the friction may lead
to damaging the heatbed.
Working with Filaments
When handled correctly, working with filaments is straightforward and safe. Please read the
following recommendations.
Always use the recommended temperatures for the selected material.
Beware of molten plastic - it can cause burns! If there is molten plastic stuck in the nozzle, do
not remove it by hand - use pliers or other tools.
Some materials may emit a strong odor when printing - regularly ventilate the room.
Handle the filament according to the instructions on the following pages of the manual.
Always make sure that the end of the filament is properly secured (either in the extruder or in
the spool). If you accidentally release the end of the filament, it may easily tangle up and create
knots.

12
1. Introduction
Thank you for purchasing the Original Prusa XL 3D printer from Prusa Research! Your support
allows us to invest in further development of 3D printers and other 3D printing products. The
Original Prusa XL is a great option for beginners, hobbyists, companies, and even for setting up a
3D printing farm.
The latest version of this handbook can be found at prusa3d.com/drivers in PDF format.
If you encounter any problems while using the printer, do not hesitate to contact us at
[email protected]. We will be happy to answer your questions or hear your ideas for
improvement. You can also visit our Knowledge Base at help.prusa3d.com or the user discussion
forums at forum.prusa3d.com.

13
2. Original Prusa XL Overview and Glossary
Extruder (Nextruder)1.
Filament sensor / Filament insertion point (on the side)2.
Spoolholder (with a spool installed)3.
Print sheet4.
LCD5.
Control Knob and Reset Button6.
USB port7.
Heatbed (moves along the Z-Axis)8.
PTFE tube / Extruder cables9.
Extruder cables and PTFE tube10.

14
Idler Nut1.
Idler2.
Nextruder body3.
0.6mm nozzle4.
Heater Block (part of the Hotend assembly)5.
Heatsink Fan6.
Gearbox and extruder motor7.
Print fan8.
Control buttons (extrude / retract filament - works only when the nozzle is preheated)9.
2.1. Contents of the Package and Accessories
Your Original Prusa XL printer package includes:
USB drive with sample prints (G-codes)
XL Tools
Silicone sock for the nozzle (see help.prusa3d.com for installation instructions)
Alcohol-saturated wipes, acupuncture needle
Double-sided Satin Print Sheet
1 kg spool of Prusament filament
These are the basic tools necessary for assembly and basic maintenance. We recommend
purchasing a few extra accessories, such as: cutting pliers (for cutting the end of filament),
isopropyl alcohol, paper wipes, and a plastic spatula (for removing plastic from the print sheet).
Not the standard 0.4mm nozzle!
The Original Prusa XL comes with a 0.6mm nozzle preinstalled. The larger nozzle diameter
offers a great detail-to-print speed ratio. If you need to print more detailed objects, you can
easily replace the nozzle with a smaller diameter model, or use an adapter and choose any V6-
compatible nozzle (available in our e-shop at prusa3d.com)

15
2.2. How to Move the Printer
If you want to move the Original Prusa XL printer, use the recommended method - pick up the
printer using the integrated holders on the sides. Due to the weight of the printer, we
recommend moving it with the help of a second person. Never lift the printer by the cables,
filament holders, and profiles on the Y-axis or the X-axis.
2.3. Disconnecting the Power Source
Always pull the connector, do not pull on the cable itself! Incorrect handling can lead to damage
to the connector or cable.
If you encounter any issues with your 3D printer, we recommend first going through the last
chapters of this manual, general print troubleshooting guides or visiting our Knowledge Base at
help.prusa3d.com. If you cannot find a solution to your problem, contact our customer support via
email at [email protected] or via chat at prusa3d.com - the Live Chat window is located in the
bottom right corner.

16
2.4. Error Screens
If the printer encounters a critical error, an error screen will be displayed with a description of
the error. The information on the screen is intended to facilitate easy identification, diagnosis and
resolution of the error. Pay special attention to the text on the screen. Most error messages are
supplemented with a QR code - scanning them (e.g. using a camera on a mobile phone) will take
you to a relevant article with instructions on how to proceed.

17
3. Your First Print
To get your printer up and running, please pay attention to the information in the following
chapters. We will go through the basics together - you’ll be printing in no time!
In this chapter you will learn how to:
Control the printer
Prepare the print sheet for the first print
Perform initial calibration
Insert filament
Start the first print
Remove the print
Troubleshoot basic issues
Update the firmware
3.1. Basic controls
All configuration steps and overall control of the printer are done with one control element - a
rotary knob. Rotate it to select items on the screen and press it to confirm your selection.
The reset button is located under the rotary knob. Pressing the reset button is the same as quickly
turning the printer off and on again. It is useful in cases where it is necessary to immediately stop
an action that the printer is currently performing.

18
3.2. Selftest Calibration (Wizard)
When you first power on the Original Prusa XL, the Selftest calibration wizard will start. The
wizard will walk you through the initial calibration and all necessary tests to start printing.
Completing the entire checklist is mandatory. But don't worry, it's gonna be super easy, barely an
inconvenience!
The purpose of the calibration is to check whether your printer is in a good shape. It's a one-
time process that doesn't need to be repeated before every print. Run it again if you encounter
issues with your printer (more on that in the advanced sections of this handbook).
The Wizard will provide you with text descriptions and illustrations of the individual steps. It
is designed to make the process as automated and understandable as possible. For clarity, some
actions are further described in the following lines.
You can also start the Wizard manually using the LCD menu - Calibration. The Wizard will require
you to install a print sheet - we will look at the correct handling in the next chapter. A
comprehensive explanation of print sheets and proper maintenance along with an explanation of
which ones are suitable for which purpose can be found in the Regular Maintenance chapter.
One of the things the Wizard will require to do is to place the print sheet onto the heatbed. Let's
do it now.
3.3. Preparing Flexible Print Sheets
Make sure there are no obstacles or objects under the heated bed, otherwise the heatbed could
crash into them when moving down.
Do not drag the print sheet across the heatbed, especially when it is attached with magnets -
you might damage the heatbed.
The Original Prusa XL comes standard with a double-sided satin print sheet. If you have a
different type, we recommend that you carefully study how to properly treat the surface. For the
initial calibration, it is enough to only wipe the bed using the supplied cleaning wipes soaked with
isopropyl alcohol. How to properly maintain different types of print beds can be found in the
Regular Maintenance chapter.
There are high-temperature magnets embedded into the heatbed that hold the removable flexible
print sheets in place. On the back of the heatbed, you will find two pins that fit exactly into the
cutout of the print sheet. Before installing the sheet onto the heatbed, make sure that it is
perfectly clean. Never print directly on the heated bed!

19
Attach the sheet by first aligning the rear cutout with the locking pins on the back of the
heated bed. (marked in orange in the picture above). Hold the sheet by the front two cutouts and
slowly lay it down onto the heated bed - watch your fingers!
Important: It is absolutely essential that the print sheet is properly attached to and aligned with
the heatbed - the cutout must match with the two pins on the rear and the bed must not be
skewed, otherwise the risk of hitting the end stops of the Z-axis arises. Be careful of your
fingers, the magnets are strong!
Before you proceed, open the packet containing the cleaning wipes soaked with isopropyl alcohol
and wipe the print bed with it.

20
3.4. Running the Selftest
During the Printer Selftest, do not manipulate or touch the printer. If the printer is placed on an
unstable surface or if there is another running 3D printer next to it, it may affect the accuracy of
the calibration negatively. The printer should be placed on a stable surface.
For the Selftest and the filament sensor calibration, you will need at least 130 cm (4.5 ft.) of
filament.
The Selftest is a set of various tests that serve as a diagnostic tool. With their help, you can
detect the most common problems, such as incorrect wiring of cables. The progress and results
of each test will be displayed on the LCD. If the Selftest detects an error, the testing will be
interrupted and the cause of the error will be displayed on the screen.
The Selftest includes:
Test of the extruder and the print fan
Test of the X, Y, and Z axis
Proper connection of the heated bed and the hotend
Loadcell test
Setting up the filament sensor - more info on inserting filament is in the two paragraphs
below
When the Selftest is completed, you can insert the filament from the spool you want to use for the
first print. If you are starting with the printer, we recommend choosing PLA for the initial print, as
this material is easy to work with and does not require complex pre-print preparation. If you don't
have PLA, read the Materials chapter carefully to learn how to properly prepare the print surface.
Whenever you insert the filament, make sure that its end is sharp and that there are no bumps or
other anomalies on the filament that would prevent it from passing through the PTFE tubes easily.
Before you insert the filament, start by placing the filament spool on the side holder. Be careful
not to let go of the end of the filament strand - the spool could easily tangle up.