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In this article, we review the Prusa XL, Prusa Researchs entry into multi-material, large-format 3D printing. Through 170+ hours of intensive testing, our engineering team assessed how this offering stacks up against its competitors in the desktop FFF market.Featuring a CoreXY configuration, the 360 mm Prusa XL stands out thanks to its tool changer with five independent toolheads, which minimizes waste compared to single-nozzle alternatives and offers a lot more versatility. Boasting a maximum 400 mm/s 3D print speed, Prusas large-format system may not sound like the fastest desktop FFF 3D printer. However, its ability to quickly switch between tool heads for different nozzle sizes or filament types enhances productivity for muti-material parts.Ideal for prototyping and engineering applications, the system also offers straightforward operation, ensuring accessibility for newcomers targeting advanced, large-scale production. Thanks to its robust design, impressive accuracy, and toolhead-switching capabilities, Prusas XL is a solid choice for professionals targeting demanding applications. Prices for the fully assembled 3D printer start at 2,599 on the official Prusa website, with the semi-assembled version available for 2,099.The Prusa XL 3D printer. Photo by 3D Printing Industry.Why choose the Prusa XL?The Prusa XL boasts a substantial build volume of 360 x 360 x 360 mm. This increased capacity unlocks more application possibilities, including large prediction runs, full-sized prototypes, and end-use parts. Given this capacity, it will not be surprising to learn that the printer itself is large, weighing 25.3 kg with 700 x 900 x 720 mm dimensions. Despite this, the XL still fits on the desktop, comfortably integrating into most workspaces.A key selling point of the 3D printer is its multi-material, five-toolhead setup, which marks a change from Prusas single-extrusion product range. Users can load up to five 2kg spools at a time, and the XL can 3D print a 10 kg object without manual interference.With speedy toolhead-swapping, users can load multiple materials and combine them into a single print job. Flexible filaments can be combined with more sturdy polymers to create functional parts, while more expensive materials can be combined with cheaper support options to lower costs and minimize waste. Different colors can also be integrated into print jobs for enhanced customization and design freedom.A look around the Prusa XL. Photos by 3D Printing Industry.A major drawback of most single-extrusion, multi-material systems is plastic waste. These systems typically purge filament when switching materials to clear traces from the nozzle. The Prusa XL overcomes this drawback by allocating each filament with its own toolhead. Purge-free functionality also speeds up multi-material 3D printing, reducing the downtime between material changes.The Prusa XLs open design is compatible with most standard 3D printing materials like PLA and PETG. However, for more challenging, sensitive filaments like ASA, ABS, and PA, Prusa offers a dedicated 3D printer enclosure. This add-on provides a stable environment with greater temperature control to prevent defeats and improve part quality.According to Prusa Research, the print profiles have been tuned to allow users to design precise parts and achieve 0.2mm accuracy. The XLs sturdy frame and tracking sensors ensure the reliable production of detailed parts. Additionally, its CoreXY motion system unlocks increased precision and speed compared to Cartesian alternatives.The Prusa XLs five toolhead assembly. Photos by 3D Printing Industry.For 3D printing newcomers, manual calibration can be an intimidating and frustrating process. The Prusa XLs loadcell sensor overcomes these challenges by automatically calibrating the nozzles starting position.Efficiency is boosted further by the XLs segmented heatbed. Powered by a separate electronic board, it features 16 individually controlled tiles to enable consistent heating and minimize deformation. Unused tiles can also be switched off to save energy.The Prusa XL enhances usability with an intuitive, easy-to-use, full-color LCD touchscreen interface. Its straightforward menus and clear instructions enable even novice users to quickly access G-code previews and print job controls.The Prusa XLs toolhead, printbed, build plate, and user interface. Photos by 3D Printing industry.How good is PrusaSlicer software?While third-party slicing software, such as Cura, is compatible with the Prusa XL, the 3D printer is optimized for use with the companys proprietary PrusaSlicer. This open-source platform is constantly being updated with new features and material profiles. Compatible with Windows, Mac, and Linux, the tool stands out thanks to its beginner-friendly interface.Through PrusaSlicer, users can modify printer settings and parameters, which are color-coded by experience level: green for beginner, orange for normal, and red for expert. Multi-color 3D printing is easily controlled within the software interface. Users can paint their desired hues directly onto their 3D models. More advanced features, such as the paint-on support tool, offer an extra level of customization for experienced makers. All material presets are meticulously fine-tuned and tested to ensure optimal printing performance.It is worth noting that certain features require specific keyboard shortcuts to access. For instance, adding text to a part involves pressing the T key, which generates a customizable text cutout. This isnt immediately apparent without reading the quick start handbook, making it a potential barrier for less experienced users.While the manual paint-on material feature is intuitive for entry-level users, it can lead to imprecise results. PrusaSlicer does offer a smart fill tool that automatically detects and fills regions with color. However, its functionality was found to be limited during testing. Therefore, we believe adding a new feature that allows users to precisely select and assign different geometric sections with specified materials would elevate precision. This would be especially valuable for those targeting demanding, professional-grade applications requiring high-quality parts.PrusaSlicer interface and Prusa XL dashboard. Images by 3D Printing Industry.The Prusa Connect cloud platform and Prusa mobile app enable remote 3D printing. Users can communicate directly with their machines, adjust print parameters, and monitor progress. Ideal for print farms, Prusa Connect allows simultaneous management of multiple 3D printers, access to live telemetry data, and tracking of material consumption.Amid growing concerns around data security, many users will be pleased to learn that offline 3D printing is also available with the Prusa XL. The 3D printer can be completely configured without a network connection, with files able to be uploaded directly via a USB stick. Prusa Research emphasizes this point, asserting that it does not collect any information about 3D printers or their surroundings, even when connected to the internet.PrusaSlicer 3D print settings and parameters. Images by 3D Printing Industry. Benchmarking the Prusa XLOur engineering team conducted 170 hours of benchmark and application testing. We started with a multi-material wrist CT scan model, one of the test files included with the printer. This part utilized three toolheads, providing an early opportunity to assess the XLs tool-changing capabilities. The bone sections were 3D printed using PLA, while TPU was used for the internal tendons to create lifelike flexibility.The model was successful at the first attempt. Free of defects, it featured clearly defined bones and joints. The efficiency of material changes significantly reduced overall downtime, eliminating material loading and purging delays. Tool changes were flawless, demonstrating a 100% success rate in picking up and parking the extruder heads.3D printed wrist CT scan. Photos by 3D Printing Industry.Repeatability is key for users wanting to produce batches of identical parts. To assess the repeatability of the Prusa XL, we 3D printed square, hexagon, and tube models 12 times each. These were then measured and compared against the intended dimensions.Most capable 3D printers are expected to achieve an average deviation under 0.1 mm and a standard deviation below 0.05 mm. All three models successfully measured below these limits, indicating impressive accuracy and precision.Repeatability square, hexagon, and tube models. Photos by 3D printing Industry.The square parts were comfortably below the benchmark, with an average deviation of 0.0836 mm and a standard deviation of 0.0168 mm. Small discrepancies were noted in the hole diameters. This is a common challenge among FFF 3D printers which often over-extrude when producing circles.Normal distribution and deviations between the measurements and references for the square models. Images by 3D Printing Industry.The hexagons achieved a 0.0378 mm average deviation and 0.0167 mm standard deviation, again reflecting solid accuracy and precision. Impressively, no bulging occurred at the corners of the hexagons, something which is often seen in competing FFF systems. This confirms that the XL is perfectly calibrated to avoid over-extrusion when fabricating sharp corners.Normal distribution and deviations between the measurements and references for the hexagon models. Images by 3D Printing Industry.For the tube model, the average deviation came to 0.0599 mm, while the standard deviation was just 0.017 mm. The dimensions for the cylinders external diameter demonstrated exceptional accuracy. However, the same cannot be said for the cylinder height, which fluctuated between 15.053 mm and 15.095 mm, consistently above the 15 mm target.Normal distribution results for the tube models. Images by 3D Printing Industry.As previously mentioned, FFF 3D printers often struggle with circles. Can the Prusa XL 3D print a perfect circle? To find out, we produced several test models, each of which featured three circular sections of 100 mm, 65 mm, and 20 mm. A mean of difference below 0.1 mm for both the X and Y axes would be considered a good result. The Prusa XL succeeded, with 0.0211mm for the X-axis and 0.0166mm for the Y-axis.3D printed circular trajectory tests. Photos by 3D Printing Industry.A common cause of imperfect 3D-printed circles is that .stl files use triangles to form meshed bodies, often resulting in jagged edges. However, PrusaSlicers Arc Fitting tool addresses this by automatically converting sharp segments into smooth arcs. This is a novel feature we have not seen in many 3D printer slicers. Our testing demonstrated its impressive effectiveness, helping the XL stand out in the desktop market. After measuring and comparing all models, the mean standard deviation was 0.0179 mm (well below the 0.05 mm threshold), while the mean of all differences was 0.0188 mm (under our 0.1 mm benchmark).The normal distribution of the circular trajectory tests. Images by 3D Printing Industry.We next tested the Prusa XL for capability. With its origins in 1970s US automotive manufacturing, this assessment leverages statistical process control to assess whether a 3D printer can reliably mass-produce parts at high volumes.During the test, we 3D printed a small tubular model 150 times. 16 were then selected at random and measured three times. Using these results, we calculated the process capability, a measure of how well the system can consistently produce parts within specified limits. We also determined the minimum process capability, which accounts for possible decentring.A score above 2.0 is optimal, while anything below 1.33 is not acceptable. The Prusa XL achieved a process capability of 3.84, well above the target. This confirms the large-format, multi-material 3D printers commendable precision, making it well-suited to high-volume production runs. Its minimum process capability score of 2.48 was also impressive, suggesting a low likelihood of part defects. This makes the XL a solid choice for users requiring reliable, repeatable performance.3D printed capability test parts. Photo and image by 3D Printing Industry.The Prusa XLs build volume of 360 x 360 x 360 mm stands out as one of the biggest in the desktop 3D printing market. But how well does the XL handle large-scale parts? To find out, we first 3D printed a slender tower reaching the 3D printers maximum advertised height. We expected a good result here, given that CoreXY configurations minimize vibrations, ensuring greater stability during production.The 360 mm Z-axis was achieved effortlessly, confirming the maximum height dimensions of the Prusa XL. A smooth surface finish and excellent layer consistency characterized the tower, a testament to the 3D printers robust frame and vibration compensation capabilities.Our perimeter test confirmed that the 360 x 360 mm X/Y axes can also be fully utilized. The part exhibited a defect-free surface, with perfect first and last layers, indicating an optimal extrusion rate. The Prusa XL is certainly a great choice for those wanting to produce large-scale parts on the desktop.3D printed perimeter test. Photo and image by 3D Printing Industry.While the XL is optimized for sizeable parts, our next test determined how well it can handle smaller, more precise components. We 3D printed a functional nut and bolt model with high tolerances and a 1.25 mm thread pitch. The model was fully functional and reproduced all intricate details to a high standard.3D printed M8 X 1.25 mm nut and bolt. Photo by 3D Printing Industry. Following this, we upped the difficulty with eight threads ranging from an M10 1.5 mm thread pitch to an M3 0.5 mm thread pitch. The XL produced accurate, functional models from M10 to M6 (1.0 mm), failing at M5 (0.8 mm). This is above average for the desktop FFF market, with most competing 3D printers only able to reach a 1.25 mm thread pitch.Nut and bolt variation test prints. Photo by 3D Printing Industry.Next, we 3D printed our in-house 3D Printing Industry benchmarking test. This model features a range of challenging geometries designed to push the 3D printer to its limits.The Prusa XL achieved a commendable, above-average score of 82.47. Large-format systems tend to struggle with high vibrations caused by their larger momentum. However, the XLs input shaper configuration minimized these challenges. This was confirmed by the models lack of defects like ringing and stringing.Prusa XL 3DPI test. Photos by 3D Printing Industry.The repeatability section performed especially well, ranking second among all 3D printers we have tested. Solid results for retraction, overhang, and accuracy were also noted. For overhangs, in particular, the XL produced successful results up to the 75 angle, significantly higher than the 50 average of most competing models.Minor issues were experienced in the flow sections of the test, with the final three negative precision cylinders, unfortunately, fusing to the main body. This was caused by PrusaSlicer failing to detect thin gaps of 0.1 to 0.2 mm.Prusa XL 3DPI test radar chart. Image by 3D Printing Industry.Testing Prusa XL applicationsNext, our team assessed how well the Prusa XL is suited to real-world applications. Beginning with a medical theme, we 3D printed an anatomical heart model using four toolheads to highlight cardiovascular features. Completed in 33 hours, the model showcased impressive detail and accuracy, with minimal defects and no color bleeding. This is a strong demonstration of the Prusa XLs multi-material capabilities, enabling a level of color-based freedom unattainable with mono-material systems.3D printed anatomic heart model. Photos by 3D Printing Industry.We also produced an induction tube with a TPU body and PLA supports. This part was downscaled to 70% for time purposes, though it still took 12 hours to complete. The Prusa XL is fairly slow, given that the standard print settings are set to 80 mm/s on the perimeters and 120 mm/s for the infill. This is necessary to help minimize the vibrations caused by its significant momentum.We attempted to print the model three times, with nozzle clogging being a recurring issue. Four false clog readings disrupted the process, indicating over-sensitivity in the XLs extruders. However, on our final attempt, we successfully produced a high-quality part. The functional prototype demonstrated excellent consiste