Voron Extrusion and Frame Guide — 2020, 2040 Profiles and Frame Assembly

Reference Build Mechanical

The aluminum extrusion frame is the backbone of every Voron printer. Frame accuracy directly determines print quality — an out-of-square frame produces skewed prints, binding motion systems, and endless calibration headaches. This guide covers everything from extrusion profiles to frame assembly techniques. Last updated: May 2025.

Extrusion Profiles

Voron printers use two primary extrusion profiles from the 20-series aluminum framing family:

2020 Profile (20mm x 20mm)

The standard profile for most Voron frame members. 2020 extrusion has a 20mm square cross section with V-slots on all four sides. Used for the Z uprights, gantry cross members, and enclosure frame on all Voron models. It is lightweight, stiff enough for non-structural members, and compatible with the full range of V-slot accessories.

2040 Profile (20mm x 40mm)

A 20x40mm rectangular profile used for the base frame of larger Voron models. The extra height provides significantly more bending stiffness in the vertical direction. Used for:

• V2.4 Base — The lower frame that holds the bed, Z motors, and electronics bay uses 2040 extrusion for rigidity.
• Trident Base — Same as V2.4, the base frame uses 2040 to support the moving bed and Z axis.

The 2040 profile is oriented with the 40mm dimension vertical, maximizing stiffness where the frame supports the heaviest loads.

Slot Types

All Voron extrusions use standard V-slot profiles. The V-shaped groove is compatible with V-slot wheels used on gantry systems and accepts standard T-nuts for mounting. Slot dimensions are:

• Inner slot channel — Accepts M3 roll-in T-nuts. Slot width approximately 5.5mm.
• Outer slot channel — Accepts M5 drop-in T-nuts. Slot width approximately 8mm.

Voron uses openbuilds-compatible V-slot. Misumi HFS series, 80/20, and generic AliExpress extrusions all work as long as the V-slot geometry matches. Avoid extrusions with incompatible slot profiles — some Chinese extrusions have slight dimensional differences that prevent T-nuts or wheels from fitting.

Cut Lengths by Model

Below are the extrusion cut lists for each Voron model. All lengths in millimeters. Cut tolerance should be within +/- 0.5mm.

Voron V0.2

Voron Trident 250mm

Voron Trident 300mm

Same as 250mm but base long/short are 400mm/380mm, Z uprights are 480mm, and cross members are 400mm/380mm.

Voron V2.4 250/300/350mm

Note: Always verify cut lengths against the official Voron documentation on GitHub. Lengths vary slightly between revisions, and some kit manufacturers use non-standard dimensions. Measure twice, cut once.

Corner Brackets

Corner brackets join extrusions at 90-degree angles to form the frame structure. Two types are used in Voron builds:

• Printed corner brackets — Designed specifically for Voron frames, printed in ABS/ASA. These are found in the official STL files and are adequate for most joints. They are lighter and cheaper than cast brackets but less rigid.
• Cast aluminum corner brackets (Misumi) — Stronger and more dimensionally accurate. Common upgrades for the base frame where precision matters most. Available from Misumi, McMaster-Carr, and AliExpress. Use M5 bolts to mount.

For structural frame joints (base frame corners, Z upright base connections), cast brackets are recommended. Printed brackets are fine for non-structural frame connections like enclosure panel supports.

Frame Assembly Procedure

1. Build on a flat surface — Use a known-flat table, granite surface plate, or piece of float glass. The frame will conform to the flatness of the surface it is assembled on.
2. Lay out all extrusions — Organize by length and position. Check that all ends are square and free of burrs.
3. Install T-nuts — Slide T-nuts into the extrusion slots before bolting. Use M5 drop-in T-nuts for corner brackets.
4. Assemble loosely — Bolt all corners together but leave hardware loose enough to allow adjustment. A 1-2mm gap at each joint is normal at this stage.
5. Square the frame — Use a machinist square to check all corners are 90 degrees. Measure diagonals — they should be equal within 1mm. Tap corners with a rubber mallet to adjust.
6. Tighten progressively — Tighten bolts in a cross pattern, re-checking squareness after each pass. Final torque for M5 frame bolts: 2.0-2.5 Nm.
7. Re-check diagonals — After final tightening, measure diagonals again. If they differ by more than 1mm, loosen and re-square.

Diagonal Measurement Method

For a rectangular frame, measure from one outer corner to the diagonally opposite outer corner. Compare with the other diagonal. If the frame is perfectly square, both measurements will be identical. A difference of 0.5mm or less per meter is acceptable. For Voron V2.4, check both the upper and lower rectangular frames independently.

Frame Materials

The most common extrusion material is 6063 aluminum alloy. It offers good corrosion resistance, is easily machinable, and provides adequate strength for 3D printer frames. Some builders upgrade to 6061 aluminum, which has approximately 50% higher yield strength. In practice, 6063 is sufficient for all Voron models — frame flex is not a limiting factor at 3D printing speeds.

Sourcing: Misumi vs AliExpress

Misumi extrusions are precision-machined, deburred, and cut to exact tolerances. They cost significantly more but arrive ready to assemble with no cleanup required. Misumi HFS series is the gold standard.

AliExpress extrusions are considerably cheaper but may require deburring and have wider tolerance ranges. Some sellers use softer aluminum alloys or slightly non-standard slot profiles that can cause T-nut fitment issues. If buying from AliExpress, read reviews from other Voron builders and stick with known vendors.

Pre-Tapped Ends vs Self-Tapping

Some extrusions come with pre-tapped M5 threaded holes at the ends for direct bolt-in corner connections. Others require self-tapping screws or bolts with T-nuts. Pre-tapped ends are more convenient but must be specified at time of order. Most Voron builders prefer T-nut connections for adjustability.

Frame Assembly Tools

• Flat, level build surface (table, glass, or granite plate)
• Machinist square (at least 4-inch/100mm)
• Digital calipers or tape measure (for diagonal checks)
• Rubber mallet (for tapping joints into alignment)
• Hex/Allen key set (1.5mm, 2mm, 2.5mm, 3mm, 4mm, 5mm)
• Torque wrench (optional, for consistent bolt tension)
• Deburring tool (if extrusions have sharp edges)