3D PRINTER FILAMENT FUSER

thingiverse

You need these items: 1. A PID temperature controller and a K-type thermocouple with M6 screw: https://www.aliexpress.com/item/Power-12V-DC-AC-Digital-Intelligent-PID-Temperature-Controller-Regulator-Thermostat-Thermocouple-K-J-sensor-Input/32705610645.html https://www.aliexpress.com/item/Wholesale-M6-Screw-Probe-K-type-Thermocouple-Temperature-Sensor-with-2M-Wire-for-Industrial-Temperature-Controller/32360367818.html 2. A Volcano aluminum block: https://www.aliexpress.com/store/product/3D-Printer-Accessories-E3D-Quick-Sprayer-Kit-Volvano-volcano-hot-end-extrusion-head-kit-heating-block/1929108_32895448677.html 3. E3D V5 throat (preferably long type) or similar M6 bolt without head (cut the head off) 4. E3D V5 heatsink (not Bowden type, tap the top to screw it to the body of the case) 5. A 60mm cooling fan 6. The most important part is this PTFE tube with ID of 1.8mm: https://www.amazon.co.uk/Fluorostore-F015156-2M-Tubing-Printer-Translucent/dp/B01ERLVLJQ 7. DC Power Socket: http://s.aliexpress.com/yyIBNRZZ 8. Rocker Switch: https://www.aliexpress.com/item/10Pcs-Ship-Type-Switch-15X21-KCD1-101-Red-2Pin-6A-250V-ON-OFF-15-21/32801619891.html 9. Brass inserts M3x4x3 and M3x5x5mm Preparing the Aluminum Block and Other Items: Get the Volcano block, drill one of the screw holes to enlarge it to 4mm in diameter (as shown), smooth out the edges so the PTFE tube can easily enter this hole. Set up the system by connecting the PID and heating element to this block, with a thermocouple that has an M6 fixing screw. Do it: Heat the block at 220-230 degrees with a PID temperature controller, place the PTFE tube into the 4mm slot of the aluminum block, cut the two sides of the filament, and fuse them in the middle of the heated PTFE tube. It's necessary to find the right method through trial and error during fusing, not pressing too much while combining the parts. When fusing is completed, take out the PTFE tube from the aluminum block, cool it with a fan immediately, and continue pressing the two ends lightly until it cools down. It's a bit difficult to combine two spools in an extra meter using this method because you'll have to slide the PTFE tube along the filament. One tip is to place a piece of the PTFE tube you regularly use in your bowden before fusing, and after fusing, use this tube as a diameter testing tube. In the pictures, red-blue connection is ABS filament, and the other blue-green is PLA.