Even though 3D printers can fabricate complex shapes that would be nearly impossible to mill, they are not well suited to designs requiring bridging or with large empty spaces. To overcome this, [Scorch] has applied an easy plastic welding technique that works with both ABS and PLA. All you need is a rotary tool.
“Friction welding” is the process of rubbing two surfaces together until the friction alone has created enough heat to join them. Industrially, the method is applied to joining large, metal workpieces that would otherwise require a time-consuming weld. In 2012, [Fran] reminded us of a toy from decades ago that allowed children to plastic weld styrene using friction. This modified method is similar to stick welding in that a consumable filler rod is added to the molten joint. Inspired by our coverage of [Fran], [Scorch] experimented and discovered that a stick of filament mounted into a Dremel works just as well for joining 3d prints.
That is all there is to it. Snip off a bit of filament, feed it into your rotary tool, and run a bead to join parts and shapes or do repairs. Friction welded plastic is shockingly strong, vastly superior to glued plastic for some joints. Another tool for the toolbox. See the videos below for [Scorch]’s demo.