Jason Susnjara

Recent Posts

Universal Plastics - Forming Customers for Life

Posted by Jason Susnjara on Wed, Mar 11, 2015

Tags: CNC, plastics, tooling, Model 67, aerospace, molds, medical, plastic trimming, vacuum forming, thermoforming, 5 axis plastics, pressure forming

Thermwood CNC machines are used across a wide variety of Industries.  One Thermwood Customer – Universal Plastics and Mayfield Plastics - are involved in the thermoforming of plastic materials.

Since Universal Plastics was founded in 1965, they have been a leader in the thermoforming industry.

The Universal plant has over 95,000 square feet and over 80 employees.  As Universal Plastics has grown, they have refined and further developed the thermoforming process to allow the manufacture of large and complex products that could never have been conceived in the previous generation. Today’s thermoformed products can match the quality and finish of injection molding, in high performance plastics, and in sizes that dwarf the capabilities of most molders.

Universal Plastics with one of their Thermwood CNC Routers

Universal utilizes Thermwood CNC machines for trimming of complex thermoformed parts as well as producing thermoforming tooling.  In fact, Universal and Mayfield Plastics have purchased 10 Thermwood C67 machines in the last seven years.

Thermoforming tooling can be built from wood, composite, cast aluminum, or machined aluminum billet. Temporary molds are commonly built of wood or composites, which can be easily machined. Permanent tools are either machined or cast aluminum, depending on the depth of the tool. Thermoforming tools can be modified easily, so changes can be made quickly and for much less money than the hardened steel tooling typical of molded parts.  For this reason alone, thermoforming is often the better process if your design hasn’t been solidified.

Universal believes quality parts are a direct result of quality tools, and take great pride in making quality machined or cast aluminum tools that deliver consistent quality products year after year. Our 5 full time toolmakers have a combined 100 years’ experience in tool and fixture making and they build many of tools in-house.

Mold makers use cast aluminum molds for larger quantities production. Aluminum molds are designed by CAD designers.  Once designed, these mold designs are transferred to Thermwood CNC routers that produce the patterns required for the final mold.

Universal PlasticsUniversal PlasticsUniversal Plastics

Also of note, the Western Mass Chapter of the National Tooling and Machining Association conduct several tours of member companies each year to give the membership a view of the diversity of the companies that do machining.  About 25 members of the WMNTMA visited Universal in February for a tour of their facility and in particular, to review the mold making and machining capabilities. Universal produces about 30% of their tooling and the balance is purchased from tool vendors around the country and area.

The Western Mass chapter has machine shops as well as vendors to the machining industry in their membership.

For more information visit www.mayfieldplastics.com and www.universalplastics.com

As Good as Wood! Make your MDF Cabinet Doors look like Solid Wood

Posted by Jason Susnjara on Wed, Feb 25, 2015

Tags: CNC, CNC Router, MDF doors, Diamond Tooling,, Solid Wood, Insert Tooling,, Cabinet Doors,

Written by Scott Burton - Sales Manager at Royce//Ayr

The latest kitchen design trends are demanding that solid wood and MDF doors appear in the same space with multi-colored cabinet layouts. This reality has challenged door makers to produce MDF doors that resemble solid wood profiles.  Production limitations have traditionally made it impossible to make MDF doors on a CNC router that match solid wood doors made on traditional moulders and tennoners.   

Advancements in MDF door tooling design and related software packages have made it possible to machine MDF doors on a CNC router that could pass as solid wood. A cohesive combination of smart tool design, flexible software, and proper material can produce an MDF product that is almost an exact match to solid wood once the door has been finished and installed. 

The application is possible, but does require some critical tools and design strategy to achieve a door with tight corners and good surface finish that can be primed with minimal sanding.  There are a couple of problems that must be overcome before achieving success.

MDF_SampleStock_26_E

Shows the current possibilities of MDF profiled doors on a CNC router.  Notice the detailed moldings and small radius on the corners of the inside profile that can be achieved.

Problem # 1 - Moulding details and tight inside corners

In previous years, a simple profile made from a single pass with a profile tool would create a rounded corner affect that made it obvious to the customer that the door was made from MDF and machined from above with a CNC router bit.  Detailed moldings and tight corners were impossible, if not very inefficient to produce.               

Solution # 1

The key to this issue is as much software related as it is tooling, and any solution must include effective communication between tool designers and software programmers.  The obvious solution to create a smaller radius in the corners is to use a smaller diameter tool.  However, this can lead to dramatically increased cycle time which can be prohibitive from a production stand point.  Primitive software made it necessary to have all tools do a complete pass around the door profile, but modern systems allow the smaller diameter tools to isolate all four corners after the larger profile tools have done their work.  The key is to start with a large profile tool to remove the majority of material and then break up the profile into small sections, and design the smallest diameter tool possible to clean the corners.  

It is important to understand the limitations of the smaller diameter tools, and adjust feed rates and RPM accordingly to avoid tool breakage. The smaller diameter tools will often be designed with single flutes, so a drop in feed rate will also ensure better cut quality.  Many small carving tools are better suited to solid carbide or carbide insert, rather than diamond due to design constraints.

Any tool inventory must include larger diameter tools for maximum material removal at higher feed rates, and matching tools with the smallest possible diameter to perform critical detailed carving applications in the corner of inside door profiles. 

Problems # 2 – Surface finish

MDF is generally very consistent and easy to finish on the outside of the panel, but profiling on the inside of the panel can create a surface that is very difficult to finish due to machining lines and “fiber tearout”.   MDF is obviously a porous material that tends to show loose fibers when machined in the core of the board. The density of MDF panel can have a dramatic impact on the resulting cut quality, but regardless of the quality of MDF it is impossible to achieve a surface finish in the core that is equivalent to the outside layer

Flat surfacing on the inside door panels is notoriously difficult as tools tend to leave machining lines on the overlapping tool path.  Depending on the fiber size in the core, tools can also pull fibers which creates a pitted affect that must be filled by primmer.  If fibers are not sheared off, they tend to raise up during priming, resulting in additional sanding or priming required.

Solution # 2

There are some machine parameter adjustments that can be made to improve surface finish.  Smaller chiploads will obviously provide less feathering of fibers, but excessively small chiploads will cause heat generation and reduced tool life, so feed rate reduction is not always ideal.  The solution lies in the tool design and cutting edge geometry.   

Pic4 Pic5

Shows an example of a diamond surfacing tool designed to provide premium surface finish on MDF door panels.  Notice the “Integrated” tool holder and tool body, which ensures optimal performance and allows tool to remove material at higher feed rates without sacrificing cut quality

The cutting edge geometry helps limit “overlap lines” between tool passes which reduces the amount of sanding required before priming.   Up shear geometry helps extract large chip loads at higher feed rates to reduce cycle time.  The diamond cutting edge is critical to providing prolonged tool life in difficult surfacing applications that produce excessive heat generation and cutting edge wear.  To achieve optimal results, it is best to run multiple tool passes and leave 3-4 mm for the final finishing pass.

Cabinet doors will always be the focal point of any kitchen, and generally require the most attention to detail.  Proper tooling design and application can help ensure the customer’s expectations are met, but also ensure that production cycle times and finishing costs are controlled.  Consult your tool designers to discover many creative ways to make your MDF doors look as good as wood.  

  

About Royce//Ayr    

resizedimage600210-royce-building

For over 4 decades Royce//Ayr has combined excellent customer service with state of the art cutting tool technology.

Royce//Ayr started out in 1963 as “Royce Carbide Tools Ltd” a small local sharpening shop for woodworking tools. The company soon became involved in the design and manufacture of specialty saw blades and cutters. In the ‘80s and ‘90s Royce started to explore the many possibilities of Insert and PCD-Diamond tooling.

1997 saw the merge of Royce Carbide Tools Ltd. with Ayr Saw & Tool Inc., a manufacturer of HSS saw blades for metal. This merger added valuable experience to the new company Royce//Ayr Cutting Tools Inc. In 2003 the company moved to a new 40,000 sq.ft. facility at 405 Sheldon Drive in Cambridge, ON.

As the industry is constantly changing and looking for better and faster ways to produce their finished products Royce//Ayr is committed to continuously investing in state of the art equipment and highly skilled employees to satisfy the demands placed on them.

Browse through this web site and inform yourself of our capabilities to produce premium quality cutting tools to internationally accepted ISO standards. You can always reach our dedicated sales and engineering staff to help design and develop the best custom tools to meet your specific needs.

With such excellent customer service and quality tooling, it’s no wonder that today Royce//Ayr is a leading manufacturer of cutting tools for wood, plastics, rubber and metal today.

Mission Statement

Royce//Ayr is committed to supplying customers with superior quality tools, excellent customer service and on-time delivery by employing cutting edge technology, tooling and machinery, and experienced dedicated employees.

 

CNC Automation Open House

Posted by Jason Susnjara on Wed, Oct 08, 2014

Tags: Thermwood, Nested Base, 3 Axis, CNC Router, Cut Ready, Cut Center, CNC Automation, Live Demonstrations

 

Open-House_Invite_Page_1Open-House_Invite_Page_2

Click to Register for the 2014 CNC Automation Open House!

 

Happy Holidays from Thermwood

Posted by Jason Susnjara on Fri, Dec 21, 2012

Tags: Thermwood, CNC Routers, CNC Router, Happy Holiday, Prosperous New Year

On behalf of the entire Thermwood family, we would like to extend our warmest wishes for a safe and happy holiday season.

Have a safe and prosperous New Year!!

 

holiday wishes thm

Thermwood Announces “YouBuild” Program to Cabinetmakers

Posted by Jason Susnjara on Mon, Jul 16, 2012

Tags: Thermwood, Woodworking, Announcements, CNC Router, cabinets, nested based, closets, manufacturing, Furniture, YouBuild, US made

 

YouBuild logo resized 600

Thermwood Announces “YouBuild”

Bringing Furniture Business to Cabinetmakers

 

Thermwood Corporation has announced a new program called “YouBuild”, a new and unique business model, providing an easy path for cabinetmakers with Thermwood CNC routers to easily address the huge home and office furniture market.

It starts with a web site, YouBuild.com, which offers over a thousand unique designs for home and office furniture and closets, some by renowned furniture designers. What makes this even more unique is that these designs can be customized and are available in four real wood species, walnut, maple, oak and cherry, either finished or unfinished. Sizes of most items can be adjusted. The wood, specially made for YouBuild by Columbia Forest Products, the largest manufacturer of hardwood plywood in North America, is high-quality, formaldehyde-free and available in any quantity through local Home Depot stores under a special order program.

Manufacturing is done locally by cabinet shops who participate in YouBuild, called “YouBuild Cut Centers”. Orders are placed online. Each Cut Center has its own online area within the YouBuild site. Products are specified, customized and quoted online. YouBuild Cut Centers access CNC programs online, using their CNC machined control, and then cut and edgeband parts that were ordered. Customers can assemble themselves, using unique joinery, or they can have the Cut Center assemble for them.

Cut Centers are not required to do any design or programming, they just sell and make what is ordered using the online programs. To help sell, they can establish Retail Dealers and Retail Design Centers. These are independent individuals and businesses that promote and sell YouBuild products for them and receive a commission on any orders they generate.

YouBuild offers an entirely new approach to furniture and, because the program is so simple and efficient, top-quality, formaldehyde-free, real hardwood materials can be used, while keeping prices highly competitive. There is no cost to become a YouBuild Cut Center as long as shops have the equipment necessary to use the technology. You can find more information in the YouBuild section of the eCabinet Systems web site and at YouBuild.com

 

ManCaveModel 011 resized 600

EZ Closet Euro

Contemporary Wave

Curve Case Pro

Thermwood Announces New Model - MTR 30DT

Posted by Jason Susnjara on Fri, Mar 16, 2012

Tags: Thermwood, eCabinet Systems, software, control nesting, 3 Axis, Announcements, CNC Router, QCore, manufacturing, panel processing, MTR 30DT

 

describe the image

Thermwood Corporation, a leading US manufacturer of CNC routers, announces the MTR 30DT dual table CNC router for machine paced panel processing.

The MTR30 DT is designed for machining jobs that require multiple tools and dual tables for nonstop machine production.  The machine is configured with two stationary 61 inch by 121 inch high flow vacuum tables with dual programmable part locators.  It is equipped with a 12 HP spindle with an automatic tool changing system that includes both fixed and at the head tooling; for a total of 20 tool positions for routing.  It also includes a drill bank with both horizontal and vertical drills, available up to 25 spindles.

MTR30 QC resized 600

 

Included within the QCore control is Thermwood’s featured Control Nesting software along with a dxf convertor for accepting dxf files for automatic nesting.  The control also includes a huge 1 terabyte hard disk for program storage and is enclosed in a dust protected air conditioned cabinet.

Visit www.thermwood.com or call 800-533-6901 or email [email protected] for more information on this product.

Thermwood is a US company with dealers and distributors worldwide.  In addition to machine manufacturing and software development, Thermwood has a technical service organization that provides support, machine installation, training, retrofits, custom programming and production assistance.

Thermwood Southeast Sales Representative, Dennis Glenn Blackburn passed away.

Posted by Jason Susnjara on Fri, Feb 24, 2012

Tags: Thermwood, plastics, CNC Routers, Woodworking, CNC Router, Dennis Blackburn, Polk Area Bicycle Association, FLC 2012 BIKE MS


Dennis resized 600

 

WINTER HAVEN, FLORIDA - Mr. Dennis Glenn Blackburn, age 62, died from multiple challenged systems Tuesday (February 7, 2012).

Dennis was born in Appleton, WI, on Jan. 10, 1950 and moved to Winter Haven from Portage, WI, in 1966. 

Dennis has been associated with Thermwood Corporation since 1990, becoming an exclusive dealer for Thermwood in March of 1997.  Dennis was highly committed to Thermwood, continuously placing in the top tier of sales every year.  “Dennis was very passionate about Thermwood, and cared deeply about all of his customers” said Vice President of Sales, Dennis Palmer.  

He was a member of the Polk Area Bicycling Association, and attended Beymer Memorial United Methodist Church.

Dennis is survived by his wife Elizabeth C. Blackburn, and daughters Celeste and Ona.

Free Online Customer Invitation from Thermwood

Posted by Jason Susnjara on Wed, Feb 08, 2012

Tags: Thermwood, software, CNC Routers, signs, sign industry, SignRouter 43, Orlando, Sign, International Sign Expo, CNC Router, ISA

 

header banner 994x resized 600

 

The International Sign Expo (March 22nd-24th) is a great way to see exciting new technologies in the sign industry.  

Thermwood has been in the sign industry for many years and will be showcasing our SignRouter 43 demonstrating the machine capabilities by machining aluminum, plastics and foam (Booth #1080).

Thermwood is offering Free Trade Show Passes to the 2012 International Sign Expo in Orlando, FL, March 22nd - 24th.  If interested, please click on the link below to regsiter for a free pass.

Free ISA Trade Show Pass Registration Link

 

 

 

eCabinet Systems Version 6.0 Build 7 Available

Posted by Jason Susnjara on Tue, Nov 29, 2011

Tags: Thermwood, eCabinet Systems, CNC, software, control nesting, software update, CNC output

 

 

ecab6 logo resized 600

Dear eCabinet Systems Members,


eCabinet Systems version 6.0 Build 7 is now available. This latest version of eCabinet Systems is available as a download only. No disc is required. It is a full install. It will either update your existing version of eCabinet Systems or complete a full install.

eCabinet Systems Version 6.0 Build 7 is ONLY a time extension release:

eCabinet Systems Update Page:
http://www.ecabinetsystems.com/ecabinet_systems_updates.htm

To obtain eCabinet Systems V6.0 Build 7, install click on the link above. Save this file to your computer then double click it to run.

If you need a new reg code, please email [email protected] or go to www.ecabinetsystems.com to generate a new code.

Sincerely,

Your friends at eCabinet Systems

CNC Automation and Habitat For Humanity work together at WMS

Posted by Jason Susnjara on Tue, Aug 30, 2011

Tags: Thermwood, Woodworking, Nested Base, CNC Router, CNC Automation, WMS, Canada, Habitat for Humanity, WMS Show

Habitat for Humanity will be the beneficiary of CNC Automation's technology and generosity at the Woodworking Machinery & Supply Expo (WMS) October 27-29.

The St. Zotique, QC-based company plans to make and assemble parts into residential casegoods at its exhibit booth throughout the three-day show, taking place for the first time ever at the Direct Energy Centre. The casegoods will be donated to Habitat for Humanity Restore in Ontario.

 

CNC Automation hatches grand plans for WMS

Making this live production possible are three production lines that CNC Automation will have in operation during WMS. They include:

Solid Wood Processing, CNC's newest division, will showcase Kentwood moulders and Ironwood classical woodworking equipment to manufacture five-piece wood cabinet doors.

Panel Processing, including Thermwood CNC nested-based routers, Omal drill and dowel insertion equipment and a panel saw, will produce case good components.

Spray Finishing & Sanding, featuring Timesavers calibration sanders, Loewer finishing sanders and Makor water-based spray systems, will be used to finish the solid wood parts. 

 m IMG  177 resized 600

 

In addition, CNC Automation is finalizing plans for a tour of Toronto-area woodworking facilities to take place on Wednesday, October 26, the day before the show opens. To assist out-of-town customers, the company has secured a block of rooms at the Fairmont Royal York Hotel conveniently located to the Direct Energy Centere.

 "We are extremely excited to see the change in venue of the WMS show," said Daniel Comeau vice president, general manager of CNC Automation. "The move to downtown Toronto has injected the market with a new enthusiasm in this important Canadian event. The WMS show is an important part of the Canadian marketplace. Canadian manufacturers deserve and should expect a "locally" based and focused showcase of products featuring the newest technologies."

"CNC Automation is committed to all of our customers Canada wide," Comeau added. "The WMS event provides us the opportunity to express this commitment to the Canadian marketplace. As a Canadian machinery dealer, we owe it to our Canadian customers to provide a Canadian event where they can view the latest technology and be exposed to new ideas that are important to their future growth and prosperity."

Please visit CNC Automation's booth at WMS in Toronto.  Booth #'s are 129 and 1504.

For more information please visit www.cncautomation.com (800.421.5955) or www.thermwood.com (800.533.6901)