SUMO ASSEMBLY GUIDE

INTRODUCTION

Thank you for your purchase of the SUMO Enclosure for the Prusa XL!

While we feel like this build is fairly straightforward, we wanted to make a detailed Assembly Guide for anyone who would like to reference a step-by-step manual. If anything seems difficult to understand, please feel free to reach out to us so that we can improve the build process for others!

FAQ

What print settings should I use?

For the SUMO Enclosure, we recommend 0.40mm or 0.32mm layer height for the body of the enclosure using a 0.6mm nozzle (the nozzle that the Prusa XL comes with).

To make it easy to print all of the parts, we will provide part sets as 3MF files.

It is important to use these layer heights because we made some overhang features specifically for the recommended layer height and nozzle diameter, so we strongly recommend using these settings in order to get the best results.

How much filament does the enclosure build require?

The SUMO requires 2.6kg of filament to print all of the blue parts in the example SUMO.

For the accent pieces, you will need approximately 300g of filament to print the black portions of the example enclosure.

Ideally, you would purchase a 3kg roll or 3 1kg rolls of one color and 1kg of your preferred accent color. Alternatively, you can print the enclosure in a single color and only need 3kgs of filament.

Of course, you are free to use whatever combination of colors that you'd like!

What type of filament should I use for the printable parts?

You can print the SUMO in any filament that you prefer, but if you intend to print regularly with high-temperature materials, we recommend using PETG, ASA, or other high-temperature materials.

For our example enclosure, we used PLA and have not had any issues as the external parts of the enclosure do not reach very high temperatures.

How long will the SUMO prints take? 

The SUMO Enclosure should take approximately 65 hours to complete using the recommended layer heights!

Good luck getting everything printed before Amazon delivers your kit!

What color should I print the parts for my enclosure?

We printed our example enclosure with PolyMaker PolyLite PLA in Stone Blue.

Be sure to share the color you pick with us on social media!

BILL OF MATERIALS

Review Bill of Materials (BOM)

BOM of SUMO Enclosure

sumo enclosure for prusa xl 3d printer BOM

***You WILL NOT use all of the included fasteners. We have included extras for future accessories and for you to customize your enclosure as needed.***

PLEXIGLASS TIP FOR ASSEMBLY

The plexiglass will come covered in a protective film. OUR CURRENT PROTECTIVE FILM IS TRANSPARENT TO CHECK FOR DEFECTS PRIOR TO SHIPPING. We recommend removing the film around the corners and around the holes as you assemble, but wait until the enclosure is fully assembled to remove the remainder of the film to avoid unnecessary scratches. Also, be careful with the door frame (especially after attaching the door) because this part that can easily be cracked.

To avoid spending an excess amount of time removing the protective wrapping, pull the wrapping TOWARDS you instead of upwards (counterintuitive but it works). This prevents the protective covering from tearing and allows you to remove the majority of the covering in a single piece. 

  • BAD FORM

  • GOOD FORM

NUT INSTALL TIP FOR ASSEMBLY

Some of the steps will involve adding press-fit nuts into the parts. If you are having trouble getting the nuts to fully seat into the part, try this tip where you use a bolt to pull the nut into the correct location.

  • STEP 1

    Grab a spare bolt and loosely place the nut in place

  • STEP 2

    Add the bolt to the hole and thread into the nut

  • STEP 3

    Using an Allen wrench, tighten the bolt until it becomes snug

  • STEP 4

    The nut should be pulled into place by the bolt from the opposite site

  • STEP 5

    Remove the bolt from the piece and repeat if needed for other nuts

SUMO ENCLOSURE PRINTS

The SUMO Enclosure is made up of 9 sets of prints (8 if you have an XL with the antenna on the side instead of the back). If you print the 9 print sets, you will be able to assemble the entire enclosure. We have created a Standard Build Print List of all required parts for the SUMO Enclosure.

For the Upper Chamber, there are a lot of different accessory parts that you can print - these prints can be found by reviewing the different part options below.

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SUMO PRINT LIST

SUMO Standard Build Print List


Print #
File
Quantity
Required?
Variations?
1
RIGHT FRONT BOTTOM
1
YES
NO
1
LEFT FRONT BOTTOM
1
YES
NO
1 BIG L GUIDE 1 YES NO
1 SMALL L GUIDE 1 YES NO
1 GUIDE PEG 2 YES NO
2
RIGHT FRONT TOP
1
YES
NO
2
LEFT FRONT TOP
1
YES
NO
3
FRONT CROSSBEAM
1
YES
NO
4
FRONT NAMEPLATE
1
YES
NO
5
RIGHT FRAME BOTTOM
1
YES
NO
5
LEFT FRAME BOTTOM
1
YES
NO
5
RIGHT FRAME TOP
1
YES
NO
5 LEFT FRAME TOP 1 YES NO
5 FRONT HANDLE SET 1 set YES NO
6 HEX RIGHT HEX BACK 1 YES FOR HEX BACKPLATE
6 HEX
LEFT HEX BACK 1 YES FOR HEX BACKPLATE
6 HEX MIDDLE HEX BACK 1 YES FOR HEX BACKPLATE
6 SOLID RIGHT SOLID BACK 1 YES FOR SOLID BACKPLATE
6 SOLID LEFT SOLID BACK 1 YES FOR SOLID BACKPLATE
7 TOP CORNER 4 YES YES
7 TOP CORNER GUARD 4 NO YES
7 SIDE CORNER 8 YES NO
7 TOP MIDDLE SUPPORT 3 YES YES
7 TOP MIDDLE SUPPORT WITH HYGROMETER 1 YES YES
7 FAN COVER 1 NO YES
7 NUT SPACER 4 YES NO
8
LCD PLATE
1
YES
NO
8 LCD PLATE GUIDE 1 YES NO
8 LEFT HINGE SET 2 YES NO
8 RIGHT HINGE SET 2 YES NO
8 HINGE BACK 4 YES NO
8 HEX LOCK 2 YES NO
8 OVOID LOCK 2 YES NO
8 FILAMENT HOLDER OFFSET 1 YES NO

9

(REAR ANTENNA ONLY)

ANTENNAE EXTENSION 1 YES YES (BIG OR SMALL)

PRUSA XL - SOLID VS HEX BACKPLATE (PRINT 6)

  • SOLID BACKPLATE (6 SOLID PRINT SET)

    The initial version of the Prusa XL had a solid backplate with 5 holes across the back of the panel.

    If you have this version of the Prusa XL, be sure to print the 6 SOLID Print Set.

  • HEX BACKPLATE (6 HEX PRINT SET)

    The more recent version of Prusa XL has a hexagon pattern cut into the backplate of the design.

    If you have this version of the Prusa XL, please print the 6 HEX Print Set.

SUMO UPPER CHAMBER PART OPTIONS (PRINT 7)

The Upper Chamber of the SUMO has a lot of customizable options for modifying the SUMO to suit your needs.

The Upper Chamber parts can be found within Print 7.

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Print 7 - TOP CORNER SELECTION

Top Corner Selection

The standard TOP CORNER part is what we recommend that most people print for the SUMO Enclosure.

top corner for delack 3d printer enclosure for prusa mk4 prusa mini prusa mk3

If you are planning to add internal wiring or something like the TP-LINK TAPO or WYZE CAM V3 to your SUMO Enclosure, we recommend printing a TOP CORNER WITH CABLE CHANNEL for better cable management. 

top corner with wire cutout for delack 3d printer enclosure

The mounts for the WYZE CAM, TAPO, and GOPRO can be found on the SUMO ACCESSORY PRINTS Page.

Print 7 - TOP MIDDLE SUPPORT SELECTION

Top Middle Support Selection

The standard TOP MIDDLE SUPPORT is used to provide support to the ceiling of the Upper Chamber of the SUMO Enclosure.
top middle support for sumo enclosure for prusa
A variation of the TOP MIDDLE SUPPORT is the TOP MIDDLE SUPPORT WITH CABLE CHANNEL. This print is designed to allow for cable management if you run wires inside of the enclosure. We recommend printing 1 Top Middle Support with Wire Cutout if you plan to add the WYZE CAM MOUNT or TP-LINK MOUNT.
delack top middle support with wire cutout for 3d printer enclosure
Additionally, if you would like to run wires out of the rear of the enclosure, consider printing the BACK TOP MIDDLE SUPPORT WITH CABLE CHANNEL.
back top middle support with cable channel for delack 3d printer enclosure

 

Print 7 - FAN COVER SELECTION

Fan Hole Cover Selection

If you DO NOT plan on adding a fan to your enclosure, consider printing a FAN HOLE COVER for the DELACK. For the bolts to fit correctly with the FAN HOLE COVER, you will need to print x4 NUT SPACER prints - these are included in the print set.

fan hole cover for the delack prusa enclosure

If you DO want to add a fan to your 3D printer enclosure, you SHOULD NOT print the Fan Hole Cover. Please choose from the options below:

Option #1: 120mm Fan

You can add a 120mm Noctua Fan without any additional prints; use the screws included in the kit to attach it to the DELACK.

CLICK HERE TO VIEW THE 120MM FAN ASSEMBLY GUIDE

120mm noctua fan for 3d printer enclosure ventilation

Option #2: 120mm Fan with HEPA Filter

If you would like to add an air filter to your fan setup, use the link below for more details on the HEPA Filter print.

CLICK HERE TO VIEW THE HEPA FILTER ASSEMBLY GUIDE

Option #3: 120mm Fan with Air Duct Attachment

To add a duct to the DELACK enclosure, print the Air Duct Attachment by following the link below.

CLICK HERE TO VIEW THE 4-INCH AIR DUCT MOUNT ASSEMBLY GUIDE

air duct for prusa 3d printer enclosure

Option #4: 120mm Fan with HEPA Filter + Air Duct Attachment

For a print set containing a HEPA Filter and an Air Duct Attachment, follow this link.

CLICK HERE TO VIEW THE HEPA + DUCT ASSEMBLY GUIDE

 120mm fan with air duct attachment for 3D printer enclosure with hepa filter

Print 7 - CORNER COVER SELECTION

Corner Cover Selection

While the corner covers are not required for the DELACK enclosure to be functional, we STRONGLY recommend that you use them. There are two options of corner covers to choose from - a version with ribs and a plain version.

Corner Cover with Ribs

3d printer enclosure corner guard with ribs

Corner Cover Plain

 

prusa 3d printer enclosure corner guard plain

Modular Top Corner

If you're looking to add some additional functionality to the corner of your printer, consider adding this Modular Top Corner Accessory Print to your setup.

CLICK HERE FOR THE MODULAR TOP CORNER ASSEMBLY GUIDE

modular top corner accessory print

 

STANDARD BUILD ASSEMBLY

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Print #1 Assembly

Print #1 Assembly

Feet

Before adding the FEET to the plexiglass, insert a rubber plug into each foot. The bottom of the rubber plug should be flat, with the side of the plug with a hole in it facing upwards, as shown below. 

insert rubber plug into feet for 3d printer enclosure

rubber plug with correct orientation for prusa enclosure 3d printer

alternate angle of rubber plug with foot for 3d printer enclosure

Add 2 nuts to each of the FEET as well (using a total of 8 nuts). The nuts should fit snugly, but you may need to use a spare bolt to pull the nut into the hex cutout.

foot with nuts for prusa 3d printer enclosure

After adding the plugs and nuts, add the FEET to the SIDE PANELS. Make sure that you add the FEET to the BOTTOM of the SIDE PANELS. The easiest way to check that you are adding the FEET to the correct side is by putting the FEET on the side of the panel WITHOUT the two holes in the middle (red circle & green circle). These two holes are for the Middle Support pieces, which are for the top of the enclosure.

top vs bottom for side panel feet for prusa 3d printer enclosure mK4

 

After adding the feet, your 3D printer enclosure should look similar to what is pictured below. 

assembly of 3d printer enclosure delack for prusa mini prusa mk4 feet

Top Corners

The TOP CORNERS have a cutout for 3 nuts per piece (2 for the sides and 1 for the top). We recommend adding the two side nuts initially, as the nuts for the top are optional and can sometimes fall out during assembly. 

nuts for top corner of the prusa mk4 prusa mini 3d printer enclosure

Once you've added the nuts to the TOP CORNERS, add the TOP CORNERS to the two side panels using bolts. The TOP CORNERS will be positioned opposite to the FEET (on the same side as the two holes in the middle for the Middle Support). Once completed, both sides should have TOP CORNERS and FEET.

3d printer enclosure delack top corner assembly prusa mini

Side Corners

Next, add 2 nuts to each of the 4 SIDE CORNERS and add these to the SIDE PANELs.

nuts for side corner of delack enclosure for prusa mini

delack 3d printer enclosure side corners assembly prusa mk4

You're done with assembly for Print #1!

Print #2 Assembly

Print #2 Assembly

Door Knob

Add 2 nuts to the DOOR KNOB BACK print.

door knob back for 3d printer enclosure delack prusa mk4

Locate the DOOR plexiglass panel, and determine which direction you would like the door to swing. Using 2 bolts, attach the DOOR KNOB and the DOOR KNOB BACK to the DOOR panel according to your chose swing direction.

door knob for 3d printer enclosure for prusa mk3 mk4 mini

The image below shows a door that will swing to the right.

door for 3d printer enclosure for prusa MINI prusa Mk4

 

 

Back Bottom Wire Cover
Locate the BACK plexiglass panel. Add the BACK BOTTOM SINGLE WIRE COVER to the enclosure as shown below using 2 nuts and 2 bolts. When you add your printer to the setup, you will be able to reposition the wire into the correct position.
back panel of 3d printer enclosure for the prusa mk4 mini mk3
3d printer enclosure cable path for prusa mk4 prusa mini
Front Middle Support
DO NO attach the FRONT MIDDLE SUPPORT yet - you need to finish Print #3 before attaching it!

Print #3 Assembly

Print #3 Assembly

Nameplate & Front Middle Support (from Print #2)

Slide your NAMEPLATE into the FRONT MIDDLE SUPPORT from Print #2. Hope you customized it!

delack enclosure faceplate nameplate for 3d printer enclosure

Add the 2 side nuts to the FRONT MIDDLE SUPPORT - you can add the top nut later.

nuts added to the nameplate on the delack 3d printer enclosure

 

Attach the FRONT MIDDLE SUPPORT to the DOOR FRAME plexiglass piece using 2 bolts.

delack nameplate for 3d printer enclosure for prusa mk4

delack door frame with faceplate 3d printer enclosure

Print #4 Assembly

Print #4 Assembly

Middle Support

After printing your MIDDLE SUPPORTS, add 2 nuts to each MIDDLE SUPPORT and attach them to the SIDE plexiglass panels using bolts.

middle support for delack 3d printer enclosure for prusa mk4 prusa mini

back panel plexiglass for 3d printer enclosure for delack prusa mini prusa mk4

If you decide to go with an alternate arrangement of MIDDLE SUPPORTS as described here, add the MIDDLE SUPPORTS to the relevant locations according to your selection.

 

 

Intermission - Wall Assembly

Wall Assembly

Now, we can assemble the walls of the enclosure. Add the BACK plexiglass panel to one of the SIDE plexiglass panels first. 

delack side panel installation for 3d printer enclosure ikea lack

Next, add the other SIDE plexiglass panel.

both sides added to the delack 3d printer enclosure

Now, add the DOOR FRAME to the front of the enclosure.

all walls assembled on delack 3d printer enclosure prusa

Getting closer!

 

Print #5 Assembly

Print #5 Assembly

Please refer to the link here for determining which HINGE to print. The HINGE print set has manual supports, so you will need to remove the supports from the part prior to installing the HINGE. The supports should break off easily using pliers.  

manual supports to be removed from 3d printer enclosure hinge

removing supports from hinges with needle nose pliers

supports removed from hinges with needle nose pliers for delack 3d printer enclosure

After removing the supports from both sides of the hinge, place the dowel rod into both sets of HINGE parts. The opening of the HINGE where the dowel rod is inserted should be facing upwards when the hinge is in its final position (as shown below). The HINGE will swing more freely over time, so don’t worry if the HINGE initially feels tight. 

 

dowel rod insertion into the DELACK 3d printer enclosure

A trick for pressing the dowel rod into place is to use the side of your needle nose pliers (or any other flat tool) to push the dowel rod into place.

needle nose pliers pressing dowel rod into hinge for 3d printer enclosure

inserting dowel rod using side of needle nose pliers

dowel rod fully assembled into the delack 3d printer enclosure hinge

After adding the dowel rod to both HINGE prints, add nuts (8 in total) to each HINGE BACK print. You may need to use the bolts to pull the nuts into position by tightening them from the opposite side of the part.

back part of hinge for 3d printer enclosure with nuts

Now, attach the HINGE to the DOOR FRAME plexiglass panel. The HINGE BACK part should fit inside the holes in the plexiglass. THIS WILL BE HARD TO TIGHTEN!! We intentionally made these parts tight so that the door would not sag. You can tighten these parts more than the other parts in this build because there is no direct contact between the metal nuts/bolts and the plexiglass (but don't overdo it). 

hinge back inserted into the door frame plexiglass panel

hinge attached to the door frame plexiglass panel for the 3d printer enclosure

both hinges assembled on the delack 3d printer enclosure

Next, add the DOOR plexiglass panel to the HINGES in a similar manner as you did previously. We recommend adding the bolts in the order mentioned below; starting with the lowest bolt lets you rest the other end of the plexiglass panel on the ground, reducing the stress on the DOOR FRAME. 

3d printer enclosure assembly steps for prusa mk4 prusa mini

Now, the door should be swinging freely. If the door does not swing correctly, try to adjust the positioning of the hinges by loosening the bolts slightly, moving the door in the direction needed, and re-tightening. 

prusa 3d printer enclosure delack assembly

Print #6 Assembly

Print #6 Assembly

Latch Set

The most important part of LATCH assembly is to make sure that the magnets are attracting each other. The magnets should fit snugly into the magnet hole, but you may need to use the side of your pliers to press the magnets into place.

delack enclosure magnet door latch

A tip for inserting the magnets is to use the side of the needle nose pliers as shown below to press the magnets into place. It is a tight fit (to prevent the magnets from getting pulled out when you open the door), so you should expect to press pretty firmly. 

magnet on side of needle nose pliers for inserting into latch for 3d printer enclosure

inserting the magnet into the hinge with the side of needle nose pliers

magnet inserted into the hinge of the delack latch 3d printer enclosure

After making sure that the magnets are attracting each other, add the LATCH set with the cutout in the design to the DELACK DOOR FRAME as shown below.

DELACK magnet latch installed on door frame for 3d printer enclosure 

Next, add the LATCH to the DOOR. Double-check that the magnets attract each other before placing them. 

delack 3d printer enclosure for prusa magnet latch assembly 

Now, the DELACK is almost finished!

DELACK enclosure assembly prusa mini Prusa MK4

Print #7 Assembly

Print #7 Assembly

Fan Hole Cover

For information about alternatives to the FAN HOLE COVER, please click here.

To install the FAN HOLE COVER, add 1 nut to each of the 4 NUT SPACER prints.

nut spacer for 3d printer enclosure delack for prusa mk4

Add the FAN HOLE COVER to the BACK plexiglass panel using 4 bolts.

back plexiglass panel with fan hole cover

 

Finishing Touches

Finishing Touches

Adding the Printer

Now is an excellent time to place the enclosure around your 3D printer. Reposition the power cable so that it runs through the opening in the back. This enclosure isn't very heavy, so it is easy to reposition and remove from around the printer entirely if needed.

pursa mk4 enclosure prusa mk3 enclosure

Adding Nuts for the Top Bolts

There are nuts and bolts to secure the top panel of plexiglass to the TOP CORNER and MIDDLE SUPPORTS. However, we like leaving the nuts out of the printed parts and inserting the bolts into the holes from the top of the enclosure to maintain alignment (without screwing them down). This allows you to remove the top easily as well. Feel free to add the nuts if you would like.

nuts for top of the DELACK enclosure

Adding the Top Panel of Plexiglass

Next, place the TOP panel of plexiglass on the DELACK. The TOP should fit snugly, but it should still be easily removable. You can add the top bolts now as well. 

top of the enclosure for prusa mk4 prusa mini

Rubber Plugs

 

Add the RUBBER PLUGS to any of the 10 filament access holes that you won't be using.  

filament access holes for the DELACK enclosure for the ikea lack

 

Add the top bolts (or not), and your DELACK Enclosure is complete! 

final delack enclosure for prusa mk4 ikea lack enclosure

Just a reminder to consider adding Print #8 (CORNER COVERS) for safety reasons! The corners of the plexiglass are pretty sharp!

delack corner covers for prusa ikea lack enclosure

 

Print #8 Assembly (recommended but optional)

Print #8 Assembly

Corner Covers

Add the CORNER COVERS to the DELACK!

delack final assembly with corner covers

Complete!

delack enclosure final fully assembled for ikea lack

delack enclosure for 3d printer alternate view

delack front main completed ikea lack prusa 3d printer enclosure

LIGHT UP YOUR PRINTER

LED LIGHT

We included an LED light with the DELACK Enclosure for a reason! Follow this Assembly Guide to install the LED Light accessory.

VIEW LED ASSEMBLY GUIDE

TONS OF MODS

DELACK ACCESSORY PRINTS

With a wide range of accessory prints, there's a print for just about any printing setup!

VIEW ALL ACCESSORY PRINTS