X1Plus Expander Board Shell (FDM Remix)

X1Plus Expander Board Shell – FDM Remix

Reliable – Easy to print – Fully usable with FDM printers

This project is a remix of the optional nylon SLS shell provided for the X1Plus Expander board.
Special thanks to Joshua Wise, creator of the original project, who kindly gave his consent for this remix.

The goal of this design is to provide an FDM-printable shell that is reliable, easy to produce, and practical for daily use.

📦 Project structure

The shell consists of:

• Upper part → X1P_EB_upper_shell.stl
• Lower part → X1P_EB_lower_shell.stl

The two parts are joined with the screws included in the X1Plus Expander kit.

The lower shell is divided into two sections:

• the base, and
• the printer attachment system (snap-fit).

This choice allows you to print the attachment in a stronger material (at least PETG) while printing the rest in PLA if you prefer. ⚠️ PLA is not recommended for the attachment itself.

🔧 Attachment system variants

Three different options are provided, depending on your needs:

1. X1P_EB_hookup.stl
   • Simplest and fastest to print (one piece, minimal supports).
   • However, more prone to breakage due to FDM anisotropy.
   • Durability depends on interlayer adhesion of the filament used.
   • Perfect for printing methods that minimize anisotropy, such as SLS or MJF printing.
2. X1P_EB_hybrid_hookup.stl
   • Adds 4 screws inserted into the sliding hook bases.
   • Significantly improves strength along the Z axis.
3. X1P_EB_hookup_screwed-base.stl
   • The “bulletproof” version.
   • Sliding hooks are printed separately with optimal orientation and then fixed to the part with the same screws used in the hybrid version.

👉 Screws used are the flat-head 2.6x8 mm ones supplied by Bambu Lab (ref. AA004) for the bed scraper kit.

🖨️ Print profiles

A single profile is provided, split across 4 plates:

1. PLA → upper and lower shell only.
2. PETG → complete version with the simplest attachment system.
3. PETG → hybrid attachment system.
4. PETG → screwed-base attachment system. Includes two sacrificial cooling cylinders to slow down the printing of the small snap-fit tab, which otherwise would be printed too quickly at the top and risk deformation.

General note: perimeter speed has been reduced for all parts.
Each object has customized settings (walls, supports, infill, top/bottom layers, etc.) for best results.

Assembly

Two short YouTube videos will guide you through the process:

How to snap the hookup system into the base.

How to attach/detach the base to/from the printer frame.

🔗 Related projects

Alongside this shell, I have also published the cases for two complementary modules:

• Andon Module Shell
• LED-Strip Level Shifter Module Shell

📜 License & remix

• Released under CC BY-SA (share-alike).
• STEP files included to encourage further remixes and adaptations.

🙌 Final note

I’d love to see your prints, remixes, and improvements — feel free to share feedback and photos!