PSU 350 W Cover

thingiverse

I am upgrading my Prusa Bear half printer with spare parts from various sources. The upgrade kit can be found on Thingiverse at https://www.thingiverse.com/thing:2562174. However, I had to purchase a new power supply unit (PSU) that has a higher wattage rating than the original and comes in a larger case. As a result, I designed a new PSU cover to fit this larger case, which is functional but not as sleek as the Prusa's design. To accommodate the new PSU, I need to drill a 4mm hole in the Z-gantry, but there is an alternative solution. If you plan to use the PSU on a Prusa Bear upgrade, mount it on the bottom mounting tab and use the existing hole in the Z-gantry to mark the position of another mounting hole on the PSU's aluminum case. Then remove the PSU, carefully drill a 3.4mm hole, and tap it with an M4 tap or screw. Be cautious not to leave any aluminum shavings inside the PSU case, as this could cause a short circuit. Remove all shavings before closing the case and mounting it on the frame. I am uploading a simple spacer that fits between the gantry and the case for better alignment. Additionally, I am providing a commented SCAD file for those who want to modify it for different mounting options or switch configurations. All mounting holes are M4 in size. UPDATE: A new version of the PSU cover, called PSU Cover V2, has been designed with improved features such as different plug and switch placement, a smaller inner reinforcement, and a larger DC outlet hole for thicker leads. This upgrade was necessary to accommodate the Prusa MK3 Power Panic board, which is soldered directly onto the plug terminals. UPDATE 2: The latest version of the PSU cover, called PSU Cover V3, offers an improved fit for Bear upgrades. A new hole has been added for outlet DC leads in the bottom of the case, allowing for longer leads and a better layout of power panic leads. Additionally, the lower mounting hole used to secure the PSU to the V-Slot Z-frame has been uncovered.