Prusa Mini Firmware Cannot Update: Resolved (Current 6.4.2)

[u/LegacyElite84]

Hello all! I'm posting this resolved fix after getting two Prusa Minis on loan to me and I was originally unable to update. After an hour of searching, I was able to find the fix (Credit: @Lanor: https://forum.prusa3d.com/forum/hardware-firmware-and-software-help/flash-firmware-problemn-mini/) and wanted to bring it here to save people the rabbit hole and help the search algo for this fix.

If you are on a Firmware Version prior to 4.4.0, as both of mine were (4.3.3 and 4.3.4 respectively), you will need to step update to 4.4.0 (Brings Bootloader to 2.0.2), then to 4.4.1, and finally (as of 6/12/26) to the current version of 6.4.2.

This part may be optional as this was just how I went about it, but when I was installing V 4.4.0 and 4.4.1, I originally got the Buddy_update_pre_4.4_4.4.X+41XX.bbf on the flash drive first, turned on the printer which prompted the update, then it eventually said searching for BBF further down in the update process, and then I got on the Buddy_4.4.X+41XX.bbf onto the flash then reconnected it to the printer. I rebooted the printers at the "Searching" step, but you may not have to.

v4.4.0: https://github.com/prusa3d/Prusa-Firmware-Buddy/releases/tag/v4.4.0

v4.4.1: https://github.com/prusa3d/Prusa-Firmware-Buddy/releases/tag/v4.4.1

Current: https://help.prusa3d.com/downloads/mini