This article is part of the Prusa XL Technical Series on INVESTEGATE.de
All guides assume that the Prusa XL Fundamentals are correct.
If not, start here:
Prusa XL Basics – Technical Fundamentals
I compared one of the first Prusa XLs from 2023 with a new Prusa XL from 2025. Prusa has made some small changes. We’ll take a closer look at these here.
1. The DWARF connection on the Nextruder
The DWARF connection cable is now attached to the Nextrudder with two M3 screws. This is because there have been frequent problems with loose connections or cable breaks. This then leads to the “Nextruder not spinning” error.
If this error occurs, you should replace these printed parts immediately. If the error occurs again, the cable is already physically damaged and must be replaced (covered by the warranty).
2. Some printed parts replaced with injection molded parts
The Display:
The Planetary Gear Cover:
The spool holders are now also manufactured using injection molding.
3. Heated bed tiles
The heated bed tiles are now glossy and no longer matte. The reason for this is unknown to me.
4. Planetary gear
The filament gear now has holes. Presumably to reduce weight.
5. Nozzle Seals
The new gray seals seal better than the old red ones. Wear is also said to have decreased.
6. Some printed parts changed from PETG to PC-CF
The filament feed adjuster is now supplied in PC-CF. PETG has caused deformation in some cases. The belt clamps are now also supplied in PC-CF. However, I’m surprised why some parts are still supplied in PETG and not PC-CF as recommended on the offcial Printables.com-Page… Especially the motor mounts…
7. The pulley O-rings have been revised twice
In 2024, Prusa replaced the pulley O-rings with thicker ones. Some parts also had to be replaced. In 2025, this was corrected again, and nylon washers are now used. However, the parts from 2024 are still compatible.
I’ve already written two blog posts about this:
Prusa XL – The new Washers for the Pulleys
Prusa XL – The new O-rings
8. Nozzle Size
The Prusa XL was initially shipped with 0.6mm nozzles. This has since been replaced with 0.4mm nozzles.
The reason for this may have something to do with multi-tool printing. 0.6mm nozzles ooze more than 0.4mm nozzles.
9. PTFE Tubes
The PTFE filament tubes have been modified. The inner diameter has become slightly larger, making it easier to insert flexible filaments.
10. Heatbed Silicone Mat
Since April 2025, the Prusa XL has become a silicone mat under the heatbed. This presumably serves to improve heat regulation and thus prevent the heatbed microcontroller from overheating.
But when I asked Prusa, I learned that it’s only for replacing the O-rings. Nothing else.
11. Software
Last but not least, the biggest changes have obviously been in the software. Many new features have been added and many improvements have been made.
Here’s a quick overview:
- Pressure Advance
- Stealth Mode
- Cancel Objects
- Phase Stepping
- Printing with different nozzle sizes
- Scarf Seams
- Touch Screen
- Filament Stuck Detection
I though I saw something about the underside of the heat bed changined? Is that right?
Yes, since April 2025, the Prusa XL has a silicone mat at the underside of the heatbed. I just updated this here on the blog. Best regards 🙂
There is a minor change you have missed. On or before May of this year, they tweaked the fan shroud on the heat break slightly.
I think the change was to mitigate filament strings from getting sucked into the heat break fan.
Hmm, I haven’t heard anything about that yet. I just looked at the Prusa XL printable parts on printables, but unfortunately I can’t find it there either.
#5 nozzle seals – the nozzle seal ‘beds’ have changed as well as the metal under seal. You can get the gray seals to sort of work without changing the other two parts, however it’s not quite right. I have started to print the replacement parts and at somepoint I will upgrade them. IN GENERAL It would be good if this guide would say which of these upgrades are cosmetic vs which ones should be considered vs which ones are ASAP.
Hey Kurt 🙂 thanks. yes its better to replace the full seal set. I will revise that again when I have the chance.