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I didn't like how the tensioning system worked on the Mini x axis. I didn't like that it depended on threads cut in to the plastic to hold tension. What I did:

I eliminated splits in the rod holes along with the screw and nut holes that went with them. No need for those any more since you do not need to pinch the rods to hold tension to keep the plastic threads from stripping due to pressure from tensioning the belt. That's a mouthful.
I added in square nuts for the tensioning screws.
I also made the holes for the screw heads shallower to give more plastic for the nuts to tighten against.
I left the screw holes smaller so you will be cutting threads in the plastic. This is so the screw has good support while tensioning. The tension is held by the square nut.
I did not change the size of the rod holes from stock.
I cleaned out the center area where the pulley goes and made it straight. The pulley is no longer captive requiring much more disassembly to remove the end piece. I will now just slip right off.

I have included the .step and .f3d files because I don't really know what people like better so you get them both.

Let me know if you try it out and if I got it right or totally screwed it up.

Update 9-9-21: Thanks to feed back I have made a couple minor changes. I moved the holes for the square nuts back towards the end making the area between the holes and the rods 1.5mm thicker. I also made the holes the screws pass through after the nuts .5mm larger so threads will not need be cut in the plastic.

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Improved X-End for Prusa Mini

Model files

Model origin

MINI+ Printable parts

License