I pre-ordered the Prusa XL with 2 toolheads on the first day of its launch. Almost two years later, I was one of the first to receive the printer.

Introduction

In this article, I’d like to share my experiences with the Prusa XL. Even though I’ll point out some issues below, I consider the Prusa XL to be a very good printer, and thanks to its special tool changer, it’s currently unrivaled in its price range.

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Initial problems with the Prusa XL

At first I had some problems with the Prusa XL, which is why I was quite dissatisfied with the Prusa XL at first.

1. Multi-color prints had some contamination.
2. Heavy stringing.
3. Left Z-spindle ran very unevenly.
4. No Estep calibration of individual extruders possible.

Especially with multicolor printing. Most of it was firmware-based, though. At that point, I wasn’t sure if I wanted to keep the printer…

Lots of stringing and bleeding

The problem has been resolved in several areas. First, the Prusa XL is very sensitive to moisture in the filament. Therefore, drying all filaments on the XL is absolutely necessary to prevent stringing. Furthermore, it is very important to correctly adjust the nozzle seals for the parked tool heads.

Non-circular Z-spindle

The left Z-spindle was running very unevenly. I contacted Prusa Support about this. They said it was completely normal and within the tolerance range. So I “forgot” about it for the time being. More on that later 😉

E-step calibration and limited EEPROM

I also discovered that it’s not possible to save values ​​to the EEPROM via the Octoprint terminal or Pronterface with M500. This means that it’s not possible to permanently save settings there. These are reset after a reboot. This would have required creating custom firmware. However, installing this would require jailbreaking the buddy board, which would have voided the warranty. So I “forgot” about this for now. However, when introducing the Prusa Core One printer, Prusa announced that breaking the seal on the buddy board would no longer void the warranty.

I would like to perform a separate E-Step calibration for all tool heads, as the steppers don’t extrude the same amount compared to each other. (More on E-Step calibration) To save a separate E-Step value for each tool, the following parameter must be enabled in the printer firmware configuration.h:

„DISTINCT_E_FACTORS“ 

Es gibt zwar die Möglichkeit über das “Experimentelle Menü” einen eigenen E-Step Wert einzutragen. Aber eben nur einen Wert für alle Werkzeugköpfe… Ich habe bereits mehrfach den Support kontaktiert und auch einen Beitrag in Github gepostet, aber leider blieb dies bisher unbeachtet.

There is the option to enter a custom E-Step value via the “Experimental Menu”. But there’s only one value for all tool heads. I’ve already contacted support several times and even posted on Github, but unfortunately, this hasn’t been addressed so far.

The Prusa XL has proven itself

After a few months, however, the major issues were resolved, and the printer was producing good prints. I upgraded from 0.6mm nozzles to 0.4mm nozzles. Features like Input Shaper, Pressure Advance, and Phase Stepping made the printer significantly better and faster. From that point on, I was quite satisfied with the printer. I then upgraded to 5 tool heads in 2024.

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Other problems with the Prusa XL

Unfortunately, at the end of 2024, further issues arose, which I discussed with Prusa Support. They then suggested that it would be better to return the printer to Prusa for inspection. The following issues were identified:

1. Both Z-spindles are running unevenly. The left one significantly more so. This results in artifacts in the print image.
2. Several belt idler pulleys are squeaking.
3. The belt tension cannot be adjusted evenly, resulting in inconsistent alignment on the left and right sides. I have about 77 Hz on the left and 85 Hz on the right. There is a 2 mm gap at the front right. There is no gap on the left.
4. My satin print bed was damaged due to a tool crash. (Firmware error?! BFW-6259) https://github.com/prusa3d/Prusa-Firmware-Buddy/issues/4337

I took pictures and videos of this, which I also shared with Prusa Support. You can watch them here: https://drive.google.com/drive/folders/1Wfqnj6k0Hxw1biUKcDIzJkP_tR2lbEfg

The return shipment

Prusa quickly sent me a shipping container for the return shipment. Packing the printer was quite simple and straightforward. Prusa also provides good instructions for this: https://help.prusa3d.com/guide/packing-the-xl-multi-tool-for-return-original-packing-material_510169

Prusa also provides you with a PDF form that you have to fill out:

You must document the packing process with photos. These photos must then be forwarded to support. They will then check them for accuracy, and only then will you receive a shipping label. The printer will then be picked up from the specified address on the agreed date.

This is what it looks like when packaged. Wrap it in cling film to protect it from moisture. You should also attach “Handle with care” signs.

The pickup took place the very next day and 3 days later the printer was back at Prusa.

Initial diagnosis of Prusa

2.5 weeks later, I received the following response from Prusa Support:

My Prusa XL has now been checked and the repair is now starting.

The repair is complete

Twenty days later, I received a response from support. The repair is now complete. I received this report:

I couldn’t tell exactly what had been replaced from the log. Upon inquiry, I learned that the Z-motors and the belts with idler pulleys had been replaced.

I was also told to recalibrate the printer upon receipt. This should always be done after such a transport.

I also ordered a few items from the Prusa Shop, which will be sent to me with the printer free of shipping costs.

I received a shipping confirmation 8 days later. It will be shipped via DHL Express and will arrive within the next 3-4 business days.

Got it today. 3 workdays later to Germany.

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Checking my returned Prusa XL

Unfortunately, I noticed several problems shortly after unpacking:

1. The belt tension is not even. On the left, it’s 83 Hz and on the right, it’s 91 Hz.
   • 1.1 The Y-carriage alignment is not even. There’s no gap on the left. On the right, there’s a gap of about 1-2 mm.
2. The Z-spindle guide on the left side wasn’t completely loose.
3. The drive pulley on the XY motor on the left side is misaligned.
4. Idler pulleys were not completely or partially replaced.
5. The damaged satin sheet was not replaced.

And those are just the problems I discovered without assembling it. I hope there aren’t any more! My Prusa XL has been missing for almost two months, and this is the result? Doesn’t Prusa do proper quality control?

Because of errors number 1, 1.1, 4 and 5, among others, I sent my printer back to Prusa for repair.

Errors number 2 and 3 should have been discovered during quality control, but as you can see, they weren’t.

You can see all pictures and videos here: https://drive.google.com/drive/folders/1KmxROzlEX0VVeef5ByVzLsx0BDgQPHpf?usp=sharing

I am very disappointed about the poor performance of Prusa support.

Replacement Printer

The very next day, support apologized profusely and repeatedly. They told me they would learn from their mistake and prevent this from happening in the future again.

I subsequently received a replacement printer via DHL Express in five days. I will unpack and test it in the next few days.

I also received a new satin sheet. And as an additional apology, I was allowed to choose two 1 kg rolls of Prusament for free.

As soon as I’ve tested the new printer, I’ll post my final conclusion here.

I’ve now tested the new printer thoroughly. It’s been running smoothly so far, and I’m finally completely satisfied with it.

Happy printing 🙂