Items talked about in this video:
Friction welding isn't anything new but its a technique that can be utilized for joining two prints together with relative ease.
In this video, I talk about friction welding with a Dremel tool and demonstrate the process.
Friction welding is a process in which a material is heated by the friction of the material spinning rapidly and rubbing against the surfaces you wish to mate, causing it to melt and bond within the gaps between the parts.
To give it a shot yourself, you'll need just a few things:
A rotary tool
Two parts you wish to join (check out my weld helpers if you just want to practice)
Filament to use as the weld material
A razor blade
Here's a quick step by step to help understand the concept well enough to give it a go on your own:
Insert a small amount of filament into the chuck on your rotary tool and ensure its not curved or bent
Set the speed to a low/medium-low speed to start
Place your two parts in the configuration you'd like them to be joined
Turn the rotary tool on and set it perpendicular to the print (angled doesn't seem to work well here)
Apply light pressure to the rotary tool while it spins and as it melts, drag it along the seam
If you seem to be punching through either of the pieces, either slow down the rotary tool or apply less pressure
Replace the filament as needed
Once the welds are complete, use a razor to clean the seam up and make it flush. Finish with wet sand paper to get the best result