Filament Fuser Electronics & Hardware Kit

img_4914     filament fuser pic


UPDATE 1: This product is totally SOLD OUT!

If you want to try to DIY there are links below for all the hardware and the electronics.

UPDATE 2: I have since moved on to using a different solution for using the last bit of filament on the roll. You can read about the “LOW FILAMENT ALARM HERE


This page about building the “Filament Fuser Block” as seen on here. The finished device can be used to fuse together two ends of FDM 3D printing filament, any size and any material!

The associated 3D Printable files are available for FREE on here.

PLEASE BE AWARE: This device is designed & intended to be controlled by your existing 3d printer controller. This is super easy to do on a reprap printer, but may be difficult for some commercial devices. If you need a stand-alone controller, my recommended solution is to get the cheap complete reprap ramps kit and just use it for this purpose. (After you get it setup you won’t even need to connect it to your computer) Control kit available here and a power supply for it here.


Assembled: Machined aluminum heater block, heatsink, Fan, heater, thermocouple, wiring, 2 pin connectors 1
Steel Bolts 4
Steel Nuts 4
Steel Rod 3mm 1
Steel Rod 1.75mm 1


DIY Non-Printed Parts List
What QTY (ea or Inches) Where
Wire Harness 36″
electrical wire, 36″ x 2 for fan 72″
2 wire pin connector 2 Not sure where to get online
fan 1
heater 1
bolts 3″ 4
Threaded rod 3″ x 1/4″-20 1
Jam nuts, 1/4″-20 13
Fender washers, 1/4″ 6
thermocouple + wire+pins 1
thermal glue 1
Drill Rod 3mm, by X” 1.75″
Drill Rod 1.5mm by X” 1.75″
Aluminum Block 0.5″x1″ by X” 1.25″
Heatshrink 1

2D Drawing for the machined block:


Assembly Instructions :

PTFE Tape Insulation on Rod Block & thermal adhesive

(Above two steps are already take care of for you, shown for reference. Print out the 3D printed parts and proceed below)

img_4908    img_4725pressed nuts    filament fuser connections    install fane before block assembly   img_4916    snug    img_4909    img_4919    img_4911  img_4920    last connection

How to fuse filament:

The secret to getting a good bond is a combination of good tool and the right technique. First warm up your Block by plugging it into your 3D printer controller. Just borrow the same set of pins that your extruder uses.

Then take about 1” of filament in each hand and follow this quick procedure.

  1. Push the filament into the side of the block for a couple seconds until it starts to mushroom out. (so you know it’s hot)
  2. Push the separate pieces together using the top groove as a guide.
  3. Slide the fused filament from the guide so that you scrape off the mushroomed material, leaving a smooth side.
  4. Side the fused filament through the side groove to remove the rest of the mushroom.
  5. Hold the bond in front of the fan until it cools.
  6. If necessary use the various edges of the block to scrape off any excess material or re-smooth the bond.

Let your slicing software to tell you how much filament the print needs and divide that length into segments to choose where certain colors will show up.

fusion technique fusion prep instructions

filament fuser    img_4942


Relevant Video Support/Demonstations:


Questions or feedback? Leave a comment below!


    • HI Kyle, at this point I dont have any order links on the product page as I am moving everything to a new storefront and focusing all my efforts on my new robot kits. For the
      fusers all I have left are the blocks by themselves now. $10 Ea + $3 shipping anywhere in continental US. If you want, pm me your shipping address and I can send you an invoice and get it out within a day or so.


  1. I know it’s been awhile but do you have any fusser blocks left? I would be very much interested in purchasing one if you have them.


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