North Country Nests Parts

PRUSA MK4S · PETG · v1.1

Overview

Shared Core Parts

Roof System

Add-On Modules

Assembly & Reference

North Country Nests · Technical Documentation

Modular Birdhouse
Part Library v1.1

Complete dimensional specifications, connection geometry, PrusaSlicer print profiles, and assembly instructions. Optimized for Prusa MK4S with PETG. Updated from Bambu X1C spec.

PRUSA MK4SPETG PRIMARY250×210×220mm BED0.4mm NOZZLEOPEN FRAME29 UNIQUE PARTS

SECTION 01

System Architecture

All North Country Nests parts share a common 127×127mm (5″×5″) interior floor module grid. Every wall, floor, and roof part is designed around this base unit.

⚠

Prusa MK4S bed is 250×210×220mm — smaller than the Bambu X1C we originally spec'd for. All parts still fit: wall panels (151×152mm) fit in both axes. Floor plate (151×151mm) fits. Roof halves (175×103mm) print flat and fit easily. The main constraint is the 210mm Y-axis — keep wall panels oriented with the 151mm dimension along Y.

🎨

No AMS / multi-color without MMU3: The Prusa MK4S is single-extruder by default. The Prusa MMU3 add-on (~$300) enables multi-material printing similar to Bambu's AMS. Without it, use the single-extruder dry-brush method for brick texture (documented in Section 08). The MMU3 is worth adding for production runs — it handles the brick color workflow automatically.

🔗

Three connection types throughout: (1) Dovetail slide — wall-to-wall and wall-to-floor, 8mm × 4mm, 6° draft, 0.15mm clearance. (2) Bayonet twist-lock — roof-to-wall collar, 22.5° rotation, 3 lugs, spring detent click. (3) Keyed D-post — all decorative add-ons, 8mm × 4mm D-profile, 12mm engagement. Zero screws anywhere.

SECTION 02

Connection System Detail

JOINTDovetail Slide Joint

Shared

Dimension	Value
Dovetail width (top)	8.0mm
Dovetail width (base)	10.4mm
Dovetail depth	4.0mm
Draft angle	6°
Clearance (pin→socket)	0.15mm per side
Engagement length	Full wall height 152mm
Friction lock zone	Last 12mm of travel
End stop depth	3.0mm positive stop

›Pin (male) on right edge of every wall panel
›Socket (female) on left edge of every wall panel
›Slight taper in last 12mm creates friction lock — no screw needed
›Assembly direction: always slide from top → down
›Same joint rotated 90° for floor-to-wall base connection

Connection Points

Right edge → PIN

Left edge → SOCKET

Positive stop prevents over-insertion

PrusaSlicer Settings

Perimeters4 minimum

Layer height0.15mm at joint zones

Infill30% gyroid

Print dovetailVertical orientation

⚠

First print always: Print the test joint file (P001-TEST.stl — 40mm dovetail pair) before full panels. On the MK4S, PETG shrinkage is ~0.3%. If joints are too tight, increase clearance by 0.05mm in your CAD file. Target: slides with firm hand pressure only, clicks at 12mm from end.

TAP VIEW TO ROTATE

SECTION 03

Tolerances & Fit Guide (Prusa MK4S)

// NORTH COUNTRY NESTS PETG TOLERANCE TABLE · PRUSA MK4S · 0.4mm NOZZLE
// All values in mm. Measured after 24hr PETG cool-down (PETG shrinks ~0.3%)
// Updated from Bambu X1C spec — MK4S runs slightly more PETG shrinkage

DOVETAIL_CLEARANCE     = 0.18  // per-side (was 0.15 on X1C — MK4S needs slightly more)
BAYONET_CLEARANCE      = 0.22  // per-side; 0.44mm total — easy twist
KEYED_POST_CLEARANCE   = 0.12  // D-profile; tight friction fit add-ons
LAYER_HEIGHT           = 0.20  // structural; 0.12 for detail faces
WALL_THICKNESS_MIN     = 3.0   // exterior walls (weather resistance)
WALL_THICKNESS_DETAIL  = 2.0   // decorative panels, shutters
DOVETAIL_PERIMETERS    = 4     // minimum for joint strength on MK4S
INFILL_STRUCTURAL      = 25    // percent; gyroid pattern
INFILL_DECORATIVE      = 12    // percent; lightning or grid
BRIDGE_THRESHOLD       = 10.0  // mm; add support above this on open-frame printer
PETG_SHRINK_FACTOR     = 0.997 // apply to large flat panels >100mm

// OPEN FRAME NOTES (MK4S has no enclosure):
// - Use draft shield in PrusaSlicer for panels >120mm
// - Keep printer away from AC vents / drafts
// - First layer: 240°C nozzle / 85°C bed (higher than Bambu due to open frame)
// - Fan: 40% from layer 3 (not full — PETG needs gentle cooling)
// - Slow first layer: 20mm/s regardless of profile

// FIRST PRINT ALWAYS: P001-TEST.stl (single joint pair, 40mm)
// If too loose: reduce clearance -0.05mm · If too tight: increase +0.05mm

SECTION 04

Prusa MK4S · PrusaSlicer Settings

Profile	Layer	Infill	Pattern	Perimeters	Supports	Speed	Temp (PETG)
STRUCTURAL	0.20mm	25%	Gyroid	4	Organic auto	150mm/s	240°C / 85°C bed
DETAIL-FACE	0.12mm	15%	Grid	3	None (design for it)	80mm/s	238°C / 85°C bed
JOINT-CRITICAL	0.15mm	30%	Gyroid	5	None	100mm/s	240°C / 85°C bed
ROOF-PANEL	0.20mm	20%	Lightning	3	Painted only	140mm/s	240°C / 85°C bed
ADDON-SMALL	0.12mm	12%	Grid	3	None	80mm/s	238°C / 85°C bed

💡

MK4S PETG tips: Enable "Draft shield" in PrusaSlicer for any print over 120mm wide — this is critical on an open-frame printer to prevent PETG layer delamination. Use the textured powder-coated PEI sheet for PETG (not the satin sheet). Purge 10mm of filament before starting the first layer. Input Shaping is enabled by default on MK4S — keep it on, it prevents ringing on textured panels.

SECTION 05

Part Library — Shared Core

P001Floor Plate — Standard

SharedClassicSignature

Dimension	Value
Exterior footprint	151 × 151mm
Interior clear span	127 × 127mm
Thickness	6.0mm
Wall socket depth	4.0mm (dovetail bottom)
Drainage holes	4× Ø4.5mm, 20mm from corners
Post mount hole	Ø28mm centered (fits 1" EMT)
Hang loop bosses	2× M4 inserts, rear edge
Est. print time	~50 min (MK4S slightly slower)
Est. filament	~38g PETG

›Dovetail sockets on all 4 edges receive wall panels
›Drainage channels slope 1° toward holes (water sheds outward)
›Interior surface: 0.4mm horizontal grooves @ 4mm pitch (fledgling grip)
›Corner chamfer 4mm to ease wall panel alignment
›Identical for all 1-floor houses; stacked with P007 for multi-floor
›Fits Prusa MK4S bed (151mm < 210mm Y-axis) ✓

Connection Points

↑ Top: 4× dovetail sockets → P002/P003/P004

↓ Bottom: Ø28mm post sleeve OR M4 hang bosses

PrusaSlicer Settings

ProfileSTRUCTURAL

Layer0.20mm

OrientationFlat on bed — no support

Draft shieldYes (open frame)

TAP VIEW TO ROTATE

P002Wall Panel — Smooth (F/L/R/B variants)

SharedClassicSignature

Dimension	Value
Width (exterior)	151mm
Height	152mm
Wall thickness	3.0mm exterior
Dovetail pin (R edge)	8mm top × 10.4mm base × full height
Dovetail socket (L edge)	Mating, 0.18mm clearance (MK4S)
Roof collar slot (top)	14mm bayonet lug slot
Entry hole cutout	Ø52mm (P005 universal insert)
Vent slots (rear only)	2× 6mm × 2mm at top edge
Est. print time each	~60 min (0.20mm structural)
Est. filament each	~45g PETG

›P002F=front (entry hole), P002L=left, P002R=right, P002B=rear (vent slots)
›Entry hole uses universal Ø52mm cutout — P005 insert snaps in
›Shutter D-post bosses flanking entry on P002F
›Top trim band switchable to MMU3 color 2 at top 12mm
›Fits Prusa MK4S: 151mm < 210mm, 152mm < 250mm — print vertical ✓

Connection Points

← Left edge: dovetail socket

→ Right edge: dovetail pin

↓ Bottom: horizontal dovetail → P001

↑ Top: bayonet lug slot → P010/P011

Face: 2× D-post bosses for shutters / add-ons

PrusaSlicer Settings

ProfileJOINT-CRITICAL at edges

OrientationVertical, face outward

Variable layer0.15mm joints / 0.20mm body

Draft shieldYes — critical at 152mm height

TAP VIEW TO ROTATE

P003Wall Panel — Clapboard TextureP004Wall Panel — Brick Texture

Same base dimensions as P002. Direct swap. Choose texture based on your home's exterior.

P003 · Clapboard

Rib relief depth0.8mm proud

Pitch8mm horizontal

Single extruderEmbossed ribs — print as-is

MMU3 methodTrim color at top band only

Extra time+8 min vs P002

Extra filament+3g

P004 · Brick Running Bond

Mortar recess depth0.6mm

Brick size19 × 9mm + 2.5mm mortar

Single extruderPrint in brick color, dry-brush mortar

MMU3 methodSlot 1: brick, Slot 2: mortar

MMU3 layer switchEvery 2.5mm (mortar height)

Extra time+25 min (MMU3 purge tower)

🖌️

Single extruder brick (recommended for first run): Print P004 in terracotta PETG. After printing, use a stiff brush to apply light grey acrylic craft paint into the 0.6mm mortar recesses. The recessed geometry catches the paint automatically. Wipe the face clean with a damp cloth while still wet. Takes ~5 min per panel. Looks excellent at farmers market display distances.

P010/P011Gable Roof Half — Left + Right

SharedClassicSignature

Dimension	Value
Panel width (at base)	103mm per half
Panel length (ridge→eave)	175mm
Pitch angle	35° (Classic) · 45° (Manor)
Overhang — eave	12mm beyond wall face
Panel thickness	3.5mm
Ridge joint	Male/female tongue 6mm × 4mm
Bayonet collar	Integrated into base edge
Vent gap at ridge	6mm intentional gap (required)
MK4S bed fit	175×103mm flat — fits 250×210 ✓
Est. print time each	~75 min
Est. filament each	~52g PETG

›P010 (left) + P011 (right) are mirror images — different STLs
›Ridge tongue/groove holds panels together at peak — friction fit
›6mm vent gap is intentional — required for bird thermoregulation
›Bayonet collar locks to wall ring — 22.5° twist to lock or release
›Chimney post boss integrated at P010 rear quadrant
›Print flat on MK4S bed — no support needed (design eliminates overhang)

Connection Points

Ridge: P010 tongue → P011 groove (friction)

Base: bayonet collar → wall ring (22.5° twist)

Rear boss: D-post receiver for chimney P020

Peak boss: D-post receiver for vane P027 / finial

PrusaSlicer Settings

ProfileROOF-PANEL

OrientationFlat · shingle face up

SupportNone

Draft shieldNot needed (flat)

TAP VIEW TO ROTATE

SECTION 06

Classic Build Order

All tool-free. Assembly time target: 8–12 minutes.

// CLASSIC BUILD SEQUENCE — target 8 min · Prusa MK4S PETG parts
// Parts: P001, P002F, P002L, P002R, P002B, P005-32, P006, P010, P011, P012

STEP 1  Place P001 floor plate flat. Identify front edge (post hole toward rear).

STEP 2  Slide P002B (rear wall) into floor rear dovetail.
        Direction: top → down. Feel/hear click at end-stop.

STEP 3  Slide P002L (left wall) into floor left socket AND P002B left socket.
        Both joints engage simultaneously.
        ★ Angle in at 15° first, then push straight down.

STEP 4  Slide P002R (right wall) into floor right socket AND P002B right socket.

STEP 5  Snap P005-32 entry insert into P002F cutout. 4 snaps click.

STEP 6  Slide P002F (front wall) into floor front AND P002L + P002R sockets.
        ★ This is the key step — 3 dovetails engage simultaneously.
        ★ Tilt forward 10°, align all 3 pins, push straight down.

STEP 7  Press P006 perch bar into D-post bosses on P002F.
        Push until flush with wall face.

STEP 8  Place P010 (left roof) on wall ring. Align bayonet lugs to slots.
        Push down → twist clockwise 22.5° until detent click.

STEP 9  Place P011 (right roof). Align ridge tongue to P010 groove first.
        Push ridge down, then bayonet: push + twist.

STEP 10 Slide P012 ridge cap over ridge joint. Snaps to both halves.

// OPTIONAL ADD-ONS (all press-fit, no tools):
// P020 chimney → press into roof chimney boss
// P027 vane → press into peak boss
// P021 shutters → press into P002F D-post bosses

// ANNUAL CLEANOUT (spring, before nesting season):
// Twist P010 + P011 CCW 22.5° → lift off
// Slide P002F straight up and out
// Full interior accessible in <60 seconds, zero tools

SECTION 07

Interchangeability Matrix

✦ = direct swap · ~ = with adapter · — = not compatible

Part	Classic	Manor	Feeder	Townhouse	Observatory	Clock Tower	Estate	Lighthouse	Treehouse
P001 Floor Plate	✦	✦	✦	✦	✦	✦	✦	~	✦
P002 Smooth Wall	✦	✦	✦	✦	~	✦	✦	—	✦
P003 Clapboard Wall	✦	✦	✦	✦	~	✦	✦	—	✦
P004 Brick Wall	✦	✦	✦	✦	—	✦	✦	—	—
P005 Entry Insert	✦	✦	✦	✦	✦	✦	✦	✦	✦
P006 Perch Bar	✦	✦	✦	✦	✦	✦	✦	✦	✦
P010/011 Gable Roof	✦	~45°	✦	✦	✦	✦	✦	—	✦
P020 Chimney	✦	~45°	✦	✦	—	✦	✦	—	✦
P021 Shutters	✦	✦	✦	✦	—	✦	✦	—	✦
P022 Deck	✦	✦	✦	✦	—	✦	✦	—	✦
P023 Feeder Tray	✦	✦	✦	✦	—	✦	✦	—	✦
P024 Clock Tower	~	✦	~	✦	—	✦	✦	—	—
P027 Weather Vane	✦	✦	✦	✦	✦	✦	✦	—	✦
P028 Clear Panel	✦	✦	✦	✦	✦	✦	✦	—	✦

SECTION 08

MMU3 Color Profiles (Prusa Equivalent of AMS)

Requires Prusa MMU3 add-on (~$300). Without MMU3, use single-color + dry-brush method.

Style / Build	MMU Slot 1	MMU Slot 2	MMU Slot 3	MMU Slot 4	Purge est.
Classic Farmhouse	Cream PETG (walls)	Dark Brown (roof/trim)	Forest Green (shutters)	—	~15g
Classic Brick Colonial	Terracotta (brick)	Light Grey (mortar)	Charcoal (roof)	White (frames)	~32g
Manor Victorian	Warm Tan (walls)	Forest Green (roof)	Gold (trim)	White (rails)	~40g
Clock Tower Sig.	Stone (tower)	Dark Slate (roof)	Gold (clock face)	Near-Black (bg)	~25g
Custom Home Match	Primary wall	Roof/trim	Secondary trim	Accent/door	~20–45g

💡

Prusa MMU3 purge optimization: In PrusaSlicer, enable "Wipe tower" and set purge volume to 40mm³ for PETG transitions (lower than default). Order filament from light → dark in session. Use "Flush into infill" to absorb purge material without waste. The Prusa purge tower is slightly less efficient than Bambu AMS — budget 20% more purge waste per multi-color print.

SECTION 09

Texture Guide — Single vs Multi-Extruder

Texture	Relief Depth	Pitch	Single Extruder	MMU3 Method	Post-process	Recommended
Smooth / Modern	None	—	Print as-is	2-color trim band	Optional sand 400gr	Either
Clapboard Siding	0.8mm proud	8mm	Single color — ribs print clean	Trim band as color 2	None needed	Single ✦
Board & Batten	1.2mm vertical	24mm	Single color — vertical ribs	Batten as color 2	None needed	Single ✦
Brick Running Bond	0.6mm recess	19×9mm + 2.5mm	Print brick color, dry-brush mortar	Slot 1 brick, Slot 2 mortar, switch per 2.5mm	Single: 5min paint. MMU3: none	MMU3 preferred
Wood Shingle (roof)	0.4mm stagger	24×8mm	Single color — shadow from relief	Slight per-course variation	Optional dry-brush weathering	Single ✦
Log Cabin	6mm half-round logs	12mm per log	Single (wood PETG or brown)	Not needed	Wood stain PETG	Single ✦

SECTION 10

Classic Kit — Bill of Materials (Prusa MK4S)

// CLASSIC BIRDHOUSE — COMPLETE PART LIST
// All PETG unless noted · Single extruder baseline · Prusa MK4S

QTY  PART    DESCRIPTION                    GRAMS  TIME (MK4S)
───────────────────────────────────────────────────────────────
1    P001    Floor Plate                    38g    ~50min
1    P002F   Front Wall (entry hole)        45g    ~62min
1    P002L   Left Wall                      43g    ~58min
1    P002R   Right Wall                     43g    ~58min
1    P002B   Rear Wall (vent slots)         44g    ~60min
1    P005-32 Entry Insert 1.25" Bluebird    4g     ~14min
1    P006    Perch Bar                      6g     ~16min
1    P010    Gable Roof Half — Left         52g    ~75min
1    P011    Gable Roof Half — Right        52g    ~75min
1    P012    Ridge Cap                      8g     ~20min
───────────────────────────────────────────────────────────────
     TOTAL (base kit)                       335g   ~8.8hrs
     MK4S is ~15% slower than X1C — plan accordingly

// PLATE LAYOUT (250×210mm bed):
     Plate 1: P001 + P002F + P002L + P002R  (fits with draft shield)
     Plate 2: P002B + P010 + P011 + P012 + P005 + P006

// FIRST TEST SEQUENCE:
// Day 1: Print P001-TEST.stl (joint pair only, ~20min)
//        Verify dovetail fits with 0.18mm clearance
//        Adjust clearance if needed, reprint test before full panels
// Day 2: Print Plate 1 overnight
// Day 3: Print Plate 2 overnight
// Day 4: Full assembly + hang outside for weather test

Modular BirdhousePart Library v1.1

System Architecture

Connection System Detail

Tolerances & Fit Guide (Prusa MK4S)

Prusa MK4S · PrusaSlicer Settings

Part Library — Shared Core

Classic Build Order

Interchangeability Matrix

MMU3 Color Profiles (Prusa Equivalent of AMS)

Texture Guide — Single vs Multi-Extruder

Classic Kit — Bill of Materials (Prusa MK4S)

Modular Birdhouse
Part Library v1.1