[Tim Trzepacz] is working on a pretty cool MIDI controller project over on Hackaday.io. It involves, naturally, a bunch of knobs and buttons. And it’s one of these nice arcade-style buttons that broke when he slammed on his car brakes and it went flying.
He tried gluing the plastic bits back together, but we all know how that works — temporarily. Next, he thought that maybe he could 3D-print a model of the arcade button’s housing. Besides being a lot of work, [Tim] didn’t have a reliable printer on hand. But he did have filament and a soldering iron.
The rest of the story is a slightly ugly mess, but it looks like it’ll work. (And it’s on the inside of the case, after all.) A working part is a good part.
The irony here is that the original choice of 3 mm ABS filament as a printing material is that it’s cheap and available because it’s commonly used in plastic welding. And there are more elegant ways to melt the plastic than with a soldering iron. And more ways to get it melted than direct heating, like ultrasonic welding and friction welding, for instance.
But we still like to see the occasional quickly hacked together effort, at least one per day. What’s your craziest plastic welding success or failure?