A method of manufacturing a fuel injector (10, 110, 210) having high-flow orifices (320) in its tip (13, 113, 213) includes removing a bulb (332) from a fuel injector tip (13, 113, 213) having at least one spray orifice (320) with a first diameter, and friction welding a slug (16) to the fuel injector tip (13, 113, 213), including forming a fused interface of material of the slug (16) and material of the fuel injector tip (13, 113, 213). The method further includes modifying the slug (16) subsequent to friction welding the slug (16) to the fuel injector tip (13, 113, 213), including forming a new bulb (32, 132, 232) from the slug (16) having at least one spray orifice (20, 120, 220) therein with a different diameter than that of the removed bulb (332). A remanufactured fuel injector (10, 1 10, 210), and fuel injector tip (13, 113, 213), includes an injector tip body having a first tip portion (14, 114, 214) of a first material and a second tip portion (16, 1 16, 216) of a material compatible for friction welding with the first material. The injector tip body further includes a third tip portion (18, 118, 218) attaching the first tip portion (14, 114, 214) to the second tip portion (16, 116, 216), the third tip portion (18, 118, 218) including a friction weld formed during remanufacturing of the fuel injector tip (13, 113, 213).