The Ultimate Guide to Assembling 3D Printed Cosplay with either Plastic Welding or Glue (Don't forget cleanup!)

Greetings, noble cosplayers! Whether you’re crafting armor for a valiant knight or props for a mischievous rogue, assembling your 3D printed creations is an exciting adventure. While glue has long been the trusted ally of cosplayers, let us introduce a regal new option: plastic welding. Using a wood burner, this technique offers an alternative for those seeking durable bonds without adhesives. And remember, if crafting feels overwhelming, Koster’s Keep offers 3D printed raw pieces, so you can assemble and paint your way to cosplay glory!

Plastic Welding: A Noble Alternative

Plastic welding is the art of fusing 3D printed parts by melting them together, creating a strong, seamless bond. This technique works particularly well for PLA and ABS materials and is ideal for larger or more intricate builds. To embark on this welding adventure, you’ll need a trusty wood burner and a steady hand—think of it as wielding the sword of crafting destiny!

Here’s how to perform this glorious technique:

1. Prep Your Pieces: Align the edges of the parts you wish to join, ensuring a snug fit. A stable work surface is key—preferably one you don’t mind getting a little charred.

2. Heat the Wood Burner: Equip your wood burner with a fine tip, and let it heat up. You’re aiming for enough heat to melt the plastic without burning through it like a dragon’s flame.

3. Melt and Fuse: Gently run the wood burner along the seam, melting the edges of both pieces. Work slowly and steadily to ensure even bonding. Pro tip: Melt a small piece of filament as "filler material" if there are gaps.

4. Cool and Sand: Allow the weld to cool before sanding it smooth for a polished finish. Your handiwork should look seamless and royal enough for any cosplay event.

Should you still decide to go the glue route

The Noble List of Glues for 3D Printed Cosplay

• Cyanoacrylate Glue (Super Glue): Swift and powerful, this glue bonds PLA and ABS prints with ease. A favorite for those seeking instant results, it’s best wielded with precision to avoid sticky fingers or an accidental glue blob on your masterpiece.

• Epoxy Resin: A steadfast choice for creators who value durability and gap-filling prowess. Although its curing time requires patience, its long-lasting hold is perfect for heavier, sturdier cosplay pieces.

• Hot Glue: For light-duty tasks or quick fixes, hot glue is your humble squire. Though its strength isn’t always royal, it serves well for lightweight materials and foam additions. Beware the sun’s wrath—hot glue has been known to melt faster than ice cream at a summer faire.

• E6000: The glue of versatility and endurance! E6000’s flexible bond makes it perfect for cosplay elements that require movement or need to adhere to fabrics. Plus, it’s waterproof—a useful trait for outdoor cosplay adventures!

• Gloop: A specialized adhesive designed for 3D printing royalty. Gloop not only bonds but chemically welds PLA and ABS filaments, creating a strong, seamless connection worthy of battle-ready cosplay. Use Gloop for precision tasks where strength truly matters.

Cleanup Strategies: Battling the Glue Gremlins

Even the most experienced crafters encounter adhesive mishaps. If glue finds itself in places it doesn’t belong, here’s how to reclaim your creation from the sticky clutches:

• Super Glue Cleanup: Acetone is your champion here. Dab a cloth or cotton swab in nail polish remover and gently rub the area to weaken the glue. Caution is key—acetone can damage finishes or delicate details, so wield it wisely!

• Epoxy Cleanup: Before curing, a damp cloth soaked in warm, soapy water can save the day. For cured epoxy, you’ll need to call upon sanding tools or a trusty chisel for cleanup. It’s a challenge, but the reward is worth the effort.

• Hot Glue Cleanup: Warm up the glue using a hairdryer or heat gun, then peel or scrape it away carefully. Reheating works wonders for cleaning up mistakes or stray glue on your fingers.

• E6000 Cleanup: Rubbing alcohol is your ally for fresh spills; dried glue can be carefully scraped away or sanded. Slow and steady wins this battle!

• Gloop Cleanup: Isopropyl alcohol is your best bet for wet Gloop. For cured adhesive, gently sand the affected area to remove the excess without harming your print.

Raw Pieces from Koster's Keep: Unleash Your Creative Majesty!

For cosplayers who crave the joy of personalization, Koster’s Keep offers 3D printed raw pieces ready for your imagination to take the reins. These unpainted, unassembled treasures give you the freedom to craft, customize, and create something entirely your own. Whether you’re designing a heroic chestplate or an intricate tiara, Koster’s Keep makes it easy to bring your vision to life—starting from scratch.

So, noble crafters, may your glue choices be wise, your cleanup skills be precise, and your cosplay creations spark joy across the kingdom (or convention floor). And remember, when the task feels daunting, Koster’s Keep is always here to provide the foundation for your artistic journey. To the crafting court—go forth and conquer!

Cheers to your sticky successes!

Keith Koster Royal Crafter and King of Koster’s Keep