Building large components with Fused Filament Fabrication remains challenging due to limited build plate dimensions; segmentation and adhesive bonding is common, yet optimal adhesives and printing parameters require study. This work evaluates joining strategies for acrylonitrile butadiene styrene (ABS) using commercial epoxy and cyanoacrylate, pure acetone welding, and ABS-acetone blends at 5, 10, and 15 g per 50 mL. Single lap joints conforming to ASTM D3163 were prepared with line and concentric infill. Tensile tests measured tensile strength, elongation, and energy per bonded area, while microscopy and Fourier transform infrared spectroscopy assessed interfacial morphology and chemical change. Tensile tests revealed that all solvent-based joining strategies significantly outperformed commercial epoxy and cyanoacrylate adhesives, with the ABS-acetone blends even surpassing the strength of the monolithic specimens. The optimal formulation of 10 g ABS per 50 mL acetone maximized joint strength at 14.7 MPa, a 75 % improvement over the 8.4 MPa achieved by cyanoacrylate. Line infill patterns consistently delivered higher strength, attributed to raster alignment with shear and increased contact, while concentric infill provided greater elongation through greater local compliance and shear yielding. Microscopy and spectroscopy confirmed the mechanism as solvent-driven chain interdiffusion, which created a graded, conformal interphase, in contrast to the sharp boundaries and voids observed with traditional adhesives. These results demonstrate that the proposed up-cycled adhesive blend enables the fabrication of large-scale ABS components with joint strength exceeding that of the base material.
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