<h1>Handheld M12 Extrusion Welder</h1> <h4>Sunday 25 January, 2026</h4> ## 2026 Projects #### Something interesting goes here <img src="media-2026/05-kf-welder.jpg" alt="Screencap of the welder from Killing Floor game" style="width:40%"> <legend>Screencap of the welder from Killing Floor game</legend> <br> The original concept is that some prints need finishing or fixing manually, and larger objects built by joining multiple smaller prints or more complex multiple-orientation prints could be welded together using the same base material as the print. I was intending to use leftover or snapped filaments as the weld filler, so this would mean using a spare extruder mechanism and some kind of stepper controller attached to a manual trigger and some heating element with tmperature conttrol. You could adjust the speed with a wheel. // Add image of current filament welder prototype <img src="media-2026/05-filament-welder-prototype.png" alt="" style="width:60%"> <legend></legend> <br> <img src="media-2026/05-welder-leister.jpg" alt="" style="width:60%"> <legend>This is a welder by Leister that is specifically for welding flat sheets</legend> <br> This idea developed into a pellet based system since I worked with injection moulding plastics as well and this could enable some amount of low pressure injection casting for some less detailed parts, or filling of hollow prints for improved strength. // Add screw based pellet feeder It is possible that as a prototype I would use a pellet style heater only, and use a drill chucked to the screw to turn the screw. I considered stepper motor systems but ultimately it might be easier to use something much higher torque per dollar and transportability could be (for once) a reasonable concession in lieu of a simpler heater receiver design. Lastly, I am now also considering using a system capable of recycling waste plastic. For our robotic printing setup at ETH Zürich, we produce large waste blobs that could be used again for packing or repairing prints with voids, failures or delamination issues. // Add image of hilti or sika sausage feeder <img src="media-2026/05-sika-powercure.jpg" alt="Sika Powercure Sausage Feeder" style="width:60%"> <img src="media-2026/05-hilti-sausage-gun.jpg" alt="I find sausage guns funny for some reason" style="width:60%"> <legend>I find sausage guns funny for some reason </legend> <br> A modified sausage feeder could be useful for this as the removable sausage holder is fairly easy to clean. An inductive coil could be wrapped around an aluminium barrel with a steel insert inside to transmit the heat evenly and precisely to the plastic. These sausage feeders also usually have a fixed speed or power delivery system which can enable a convenient "fixed" feed rate for melted plastic. Milwaukee's sausage feeder threads can withstand 180kg Internal diameter 50mm External diameter 54mm Concerns : - Threaded cap, pushing block and nozzle are plastic, need to machine new ones from brass? - Sealing of the pushing block against the aluminium tube Each of these are valid and useful welder types depending on the scenario. It might be most fruitful to develop the baseline induction heated receiver as a system, and then leave the pressure drive system up to the user. What couhts as done? + + + Abandoned features (with reasons) + + + Why? Too much time? Wait till next version? Not essential for enjoyment? Feature cool but not required? --------------------- ## Credits and Licencing Do the right thing and credit where it is due. I am trying to be a better person and do the same. Licence information is in the root folder of this Repo and covers everything in it unless otherwise specified. </div>