Filament Fuser Electronics & Hardware Kit

img_4914     filament fuser pic

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UPDATE: This product is SOLD OUT! All I have left are some blocks by themselves and a few baggies containing all the hardware assembled (washers, nuts, rods, block but no electrical anything.)  I sell the naked block for $10 and for a block with hardware baggie $15. Shipping = $3 anywhere in continental US.

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

 

This page about building the “Filament Fuser Block” as seen on 3DPrinting.com 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 Thingiverse.com 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.

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PACKING LIST
ITEM QTY
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

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DIY Non-Printed Parts List
What QTY (ea or Inches) Where
Wire Harness 36″ http://www.mcmaster.com/#2837K22
electrical wire, 36″ x 2 for fan 72″ http://www.mcmaster.com/#8260T11
2 wire pin connector 2 Not sure where to get online
fan 1 http://amzn.to/2lRQLpp
heater 1 http://amzn.to/2lRBuFd
bolts 3″ 4 http://www.mcmaster.com/#91309A554
Threaded rod 3″ x 1/4″-20 1 http://www.mcmaster.com/#95475A554
Jam nuts, 1/4″-20 13 http://www.mcmaster.com/#94846A029
Fender washers, 1/4″ 6 http://www.mcmaster.com/#91090A109
thermocouple + wire+pins 1 http://amzn.to/2njX4Pu
thermal glue 1 http://amzn.to/2nk1KoQ
Drill Rod 3mm, by X” 1.75″ http://www.mcmaster.com/#88625K62
Drill Rod 1.5mm by X” 1.75″ http://www.mcmaster.com/#8893K119
Aluminum Block 0.5″x1″ by X” 1.25″ http://www.mcmaster.com/#8975K11
Heatshrink 1 http://amzn.to/2njU05V

2D Drawing for the machined block: https://engineerdog.com/machine_heater_metal/

I ended up with a bag of finish machined heater blocks if anyone is interested in buying a bunch at once.

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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

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Relevant Video Support/Demonstations:

Questions or feedback? Leave a comment below!

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