Thermwood Adds Angle Layer Printing to its LSAM Large Scale Additive Systems

Posted by Duane Marrett on Tue, Nov 30, 2021

Tags: Thermwood, Announcements, Thermwood LSAM, VLP, ALP

Thermwood has added a third print orientation to its LSAM Large Scale Additive Manufacturing systems.

LSAM systems currently can print both horizontal and vertical layers if equipped with the Vertical Layer Print (VLP) option, available on most Thermwood LSAM machines. This new addition adds Angle Layer Printing (ALP) to the VLP option. Angle Layer Printing is the ability to print at a 45 degree angle.

LSAM Angle Layer Printing (ALP) shown

LSAM Angle Layer Printing (ALP) shown


LSAM Regular Vertical Layer Printing (VLP) shown

LSAM Regular Vertical Layer Printing (VLP) shown


LSAM Horizontal Layer Printing (HLP) Shown

LSAM Horizontal Layer Printing (HLP) shown


Maximum Print Flexibility

Each print orientation has advantages and limitations for a particular part design. Offering all three on the same machine, for the first time, means maximum print flexibility. All print orientations use the complete LSAM print head including exclusive LSAM print features such as the patented compression wheel and Thermal Sensor Layer Automation.

This helps maintain an even layer temperature throughout the print.  LSAM automatically adjusts the individual layer temperature to provide for superior layer fusion (as seen below).

Thermal Sensor Layer Automation

LSAM machines are currently operating in regular daily industrial production with many existing systems already equipped with Vertical Layer Print capability. The Vertical Layer Print (VLP) option has been replaced with a VLP/ALP option on new machines which offers both vertical and angle layer print capability, in addition to the standard horizontal layer print.

Angle Layer Print (ALP) can be easily and inexpensively added to machines operating in the field that already have the VLP option.

If a machine was purchased without VLP, the entire new VLP/ALP Print option, can be added to most machines already in operation. It can be done in the field, but is a bit more involved.

Angle Layer Printing Video

LSAM ALP Video

Broad Line of LSAM Systems Available

Thermwood’s LSAM large scale additive systems are the most widely used large scale composite thermoplastic additive equipment in industrial production today. Virtually all, if not all, large scale additive systems installed in the last several years have been Thermwood LSAMs. Processing a variety of reinforced composite polymers from room temperature ABS and PC to high temperature material such as PSU, PESU and PEI, they are used to produce molds and tools for the aerospace industry, patterns for the foundry industry and for a variety of other unique applications.

LineUp_LSAMrv421-2

LSAM systems are available in sizes from 5x10 foot to 15x60 foot in a variety of configurations including print only and full print and trim, making it the broadest product offering in the large scale additive arena. Print heads are available that can print thermoplastic composite material at rates from 200 pounds per hour to over 500 pounds per hour.

They have a variety of exclusive features including a temperature controlled compression wheel and automatic thermal layer speed control, both of which help assure the best possible fusion between printed layers.

With the addition of Angle Layer Print, these systems have become even more capable and more flexible.

Finished LSAM Angle Layer Print (rear view)

Finished LSAM Angle Layer Print (rear view)

finished_side_view_small

Finished LSAM Angle Layer Print (front view)

LSAM Info Request

Take a Tour of the Thermwood Model 90

Posted by Duane Marrett on Wed, Oct 06, 2021

Tags: Thermwood, Model 90, Tour

The Model 90 is a heavy-duty, high-speed five-axis CNC router specifically developed for high-speed trimming and pattern machining, and is available in single or dual moving aluminum tables with a fixed gantry.  This robust system offers a variety of options and features to tackle a multitude of different applications.

M90_510-1

Model 90 Info Request

Model 90 Tour

 

THERMWOOD LSAM Additive Printer 510 will be LIVE Printing High Temp Autoclave Aerospace Tooling at CAMX 2021!

Posted by Duane Marrett on Fri, Oct 01, 2021

Tags: Thermwood, Announcements, Trade Shows, Large Scale, Thermwood LSAM, SABIC, LSAM Additive Printers, Airtech, High Temperature, Techmer PM, CAMX

Thermwood LSAM

Live Printing

THERMWOOD LSAM Additive Printer 510 will be LIVE Printing High Temp Autoclave Aerospace Tooling at CAMX 2021!

Thermwood will be printing high temp autoclave aerospace tooling on an LSAM Additive Printer 510 LIVE at CAMX 2021 in Dallas, TX, October 19th-21st in Booth #M44B.  LSAM Research Laboratory at Purdue ADDITIVE3D simulation software will be on display as well in adjacent Booth #M44, with Purdue representatives on site for demonstrations.  We will be printing a different material each day, donated by AIRTECH, SABIC AND TECHMER PM.  This promises to be an exciting demonstration of the LSAM Additive Printer Large Scale Additive System! 

THERMWOOD LSAM Additive Printer 510 will be LIVE Printing High Temp Autoclave Aerospace Tooling at Rapid + TCT 2021

PXL_20210914_170431874

Free CAMX 2021 Exhibit Pass & 15% off Conference Registration Fee

Click the link below to Be Our Guest and register for a Free CAMX Exhibit pass and 15% off the Conference Registration Fee.

Free Exhibit Hall Pass Code: FREEEX021

15% off Full Conference Registration Code: FREEFULL21

CAMX 2021 Thermwood Free Exhibit Hall Pass Link

Make plans now to visit the Kay Bailey Hutchinson Convention Center and stop by Thermwood Booth #M44B to witness this live and in-person!


Thermwood LSAM Research Laboratory at Purdue University

LSAM Research Laboratory at Purdue ADDITIVE3D Software on Display

Representatives from the recently announced Thermwood Research Laboratory at Purdue University (located in Purdue University's Composites Manufacturing Simulation Center - CSMC) will also be on hand to demonstrate their ADDITVE3D simulation software.

Additive3D Software from LSAM Research Laboratory at Purdue University


airtech_logo-1

AIRTECH High Temp Material - Tuesday, October 19th

On Tuesday, October 19th, we will be printing AIRTECH PEI DALTRAM I-350CF


SABIC

SABIC High Temp Material - Wednesday, October 20th

On Wednesday, October 20th we will be printing SABIC LNP™ THERMOCOMP™ AM EC004XXAR1 ULTEM compound.


Techmer PM

TECHMER PM High Temp Material - Thursday, October 21st

On Thursday, October 21st, we will be printing TECHMERPM PESU 1810 3DP.


 

Are Voids and Porosity a Problem in Large 3D Printed Parts?

Posted by Duane Marrett on Wed, Sep 29, 2021

Tags: Thermwood, LSAM, Voids, Porosity

Experts say so at industry seminars, however, major aerospace companies 3D print molds every day that don’t have void or porosity problems. How can this be?

Watch the 8 minute video below and learn the simple answer.

the_truth_about_porosity_in_large_3d_printed_tooling_1_3

 

Thermwood Sponsors Racer in SCCA Runoffs

Posted by Duane Marrett on Mon, Sep 20, 2021

Tags: Thermwood, Announcements, Race Car, Sponsor, SCCA

Thermwood LSAM

Thermwood Sponsors Racer in SCCA Runoffs

Dale, Indiana based Thermwood Corporation will enter into an LSAM/Thermwood sponsorship arrangement with Columbus, Ohio based Alliance Autosport for one of Thermwood’s own employees. The employee will be racing in the Sports Car Club of America (SCCA) “Runoffs” at the famed Indianapolis Motor Speedway during the last week of September and into October.

The Runoffs is the SCCA’s annual winner-take-all national championship. The competition brings together the best qualified amateur racers from all over the US and Canada to compete across 26 different race car classes for the 58th consecutive year.

The young driver, Gabe Fehribach, is a member of Thermwood’s engineering team. Gabe fulfilled his Runoffs qualification requirements earlier this year after racing at such storied venues as VIRginia International Raceway, Circuit of the Americas, Mid-Ohio Sports Car Course, and Watkins Glen International, among others.

Thermwood Sponsors Racer in SCCA Runoffs

Following three days of qualifying beginning September 28th, Gabe will compete with his winged, open-wheel SCCA Enterprises Formula Enterprises 2 race car the morning of Friday, October 1st against 28 other drivers all running the same spec chassis, Sunoco fuel, Hoosier tires, and Mazda power unit.

Tickets for the three days of racing beginning October 1st can be purchased through the Indianapolis Motor Speedway website.

For more information on Thermwood, the SCCA Runoffs, Alliance Autosport, and Indianapolis Motor Speedway, visit these websites:

http://www.thermwood.com
http://www.scca.com/runoffs
http://www.allianceautosport.com
http://www.indianapolismotorspeedway.com

Thermwood Sponsors Racer in SCCA Runoffs


 

THERMWOOD LSAM Additive Printer 510 will be LIVE Printing High Temp Autoclave Aerospace Tooling at Rapid + TCT 2021

Posted by Duane Marrett on Thu, Sep 02, 2021

Tags: Thermwood, Announcements, Trade Shows, Large Scale, Thermwood LSAM, SABIC, LSAM Additive Printers, RAPID + TCT, Airtech, High Temperature, Techmer PM

Thermwood LSAM

THERMWOOD LSAM Additive Printer 510 will be LIVE Printing High Temp Autoclave Aerospace Tooling at Rapid + TCT 2021

Live Printing

Thermwood will be printing high temp autoclave aerospace tooling on an LSAM Additive Printer 510 LIVE at RAPID + TCT 2021 in Chicago, IL September 13th-15th.  LSAM Research Laboratory at Purdue ADDITIVE3D Software will be on display as well, with Purdue representatives on site for demonstrations.  We will be printing a different material each day, donated by SABIC, TECHMER PM and AIRTECH.  This promises to be an exciting demonstration of the LSAM Additive Printer Large Scale Additive System. 

Free Rapid + TCT Expo Pass & $100 off Conference Registration Fee

Click the link below to Be Our Guest and register for a Free Rapid + TCT Expo pass and $100 off the Conference Registration Fee.

Use Promo Code: 10016220

Free Rapid + TCT Expo Pass & $100 off Conference Registration Fee

Make plans now to visit the McCormick Center and stop by Thermwood booth #E7628 to witness this live and in-person!


Thermwood LSAM Research Laboratory at Purdue University

LSAM Research Laboratory at Purdue ADDITIVE3D Software on Display

Representatives from the recently announced Thermwood Research Laboratory at Purdue University (located in Purdue University's Composites Manufacturing Simulation Center - CSMC) will also be on hand to demonstrate their ADDITVE3D simulation software.

Additive3D Software from LSAM Research Laboratory at Purdue University


SABIC

SABIC High Temp Material - September 13th

On Monday, September 13th we will be printing SABIC LNP™ THERMOCOMP™ AM EC004XXAR1 ULTEM compound.


Techmer PM

TECHMER PM High Temp Material - Tuesday, September 14th

On Tuesday, September 14th, we will be printing TECHMERPM PESU 1810 3DP.


airtech_logo-1

AIRTECH High Temp Material - Wednesday, September 15th

On Wednesday, September 15th, we will be printing AIRTECH PEI DALTRAM I-350CF


 

Large Scale Additive Manufacturing Book Published

Posted by Duane Marrett on Thu, Aug 19, 2021

Tags: Thermwood, Announcements, Large Scale, Thermwood LSAM, Boeing, Book, Additive Manufacturing Guide

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A Manager's Guide to Large Scale Additive Manufacturing

A Manager's Guide to Large Scale Additive Manufacturing

This 315 page book, currently available as either an eBook or paperback hardcopy, is intended to help non-technical managers understand the basics behind a new technology that is revolutionizing production of large composite molds, tools and other industrial and commercial products.

Where to Purchase

This book is currently available from Amazon either as an electronic file or as a printed hardcopy.

PURCHASE ON AMAZON

 

 

Who This Book is For

If you are a manager in an industrial company who might benefit from large scale additive technology, or, if your company is actively exploring this technology, this book will give you the background you need to participate and make better decisions. It will also help you cut through the confusion and crosstalk that often accompanies a new technology like this.

More Info

Industrial additive manufacturing is currently being used successfully every day to produce some of the largest composite parts ever made. These include large aerospace molds and tools, foundry patterns for various industries, chassis for electric busses and what is likely the tallest 3D printed structure ever made. Although the process results in substantial savings and dramatically reduces lead time, much of industry today still doesn’t understand or trust it.

In this book, the author, who was instrumental in developing the technology actually being used in industry today, explains in everyday, no nonsense language what it is, how it works, what actually works, what doesn’t and why. He provides a guide for non-technical managers to help them understand the basics so they can evaluate how this new technology might impact their company.

He explores all aspects of this process in clear, easy to understand language including the print process, polymers, software, trimming, cost savings, time savings, computer simulation and the practical, real world, aspects of getting into large scale additive. He includes sometimes humorous vignettes about surprises, missteps and stumbles during initial technology development and how they were handled.

About the Author

Author Ken SusnjaraThe author, Ken Susnjara, is the founder, Chairman and CEO of Thermwood Corporation, the leading supplier of large scale additive systems for the production of thermoplastic composites. With almost 100 patents to his name, he was instrumental in the development of the underlying technology behind the most successful large scale additive systems today.

 

 

 

 

Boeing, Navy ManTech, NAVAIR AERMIP and Thermwood Collaborate on Large Scale Composite AM Cure Tool

Posted by Duane Marrett on Wed, Jun 30, 2021

Tags: Thermwood, Announcements, Large Scale, Thermwood LSAM, Navy, Composite Tooling, Boeing, Navair, Collaboration, Fleet Readiness Center

Thermwood was a key development partner in a Navy ManTech funded program issued to Boeing Research and Technology. The ManTech program was managed by Advanced Technology International (ATI) for the Office of Naval Research (ONR) with funding provided from the Naval Air Systems Command (NAVAIR) Aircraft Equipment Reliability & Maintainability Improvement Program (AERMIP). Fleet Readiness Center East (FRCE) was a key technical contributor for the low cost composite cure tooling technology development.

boeing_navair_release_8_18_21-2

Boeing, Navy ManTech, NAVAIR AERMIP and Thermwood Collaborate on Large Scale Composite AM Cure Tool

The Details

Thermwood’s Large Scale Additive Manufacturing (LSAM) machine was selected as the Large Format Additive Manufacturing (LFAM) machine to conduct the technology development. Several unique equipment features of the LSAM machine drove the selection. The high temperature autoclave cure tooling operating environment of 355 degree Fahrenheit and 85 psi provides a challenge for polymer based tool material. Additional composite cure tooling requirements for vacuum integrity and dimensional stability were validated during the development. Neil Graf Office of Naval Research, noted “Composite manufacturing is a strategic technology for future platforms and development of more cost effective tooling solutions would significantly benefit the implementation.”

The Process

FRCE provided a high contour mold line surface to Boeing for generating the composite cure tool. The mold line shape was very aggressive and would stretch the large format additive manufacturing technology processes capability. The spherically shaped portion of the mold line offered the largest challenge, as the unsupported 3D printed angle limitation of approximately 45 degrees provides an interesting obstacle to overcome for the spherical mold line section of the tool. Boeing rotated the 3D print plane 35 degrees to avoid encroachment of the build angle limitation.

Final 3D Print Model

Final 3D Print Model

The new innovative build plane approach eliminated the requirement for temporary support material for the aggressive mold line shape. The new build angle would test the LSAM machine limits in an area never explored previously. TechmerPM PESU CF 1810 high temperature print material was used for the composite cure tool. High temperature materials present additional challenges during print over low temperature materials such as ABS CF. Two interim support features were added to compensate for the center of gravity shift of the print. The LSAM machine performed flawlessly during the composite cure tool print. The tool was printed in 7 hours and 26 minutes using 610 lbs of material.

Composite Cure tool printing on Thermwood LSAM

Composite Cure Tool printing on Thermwood LSAM

The composite cure tool was machined in 53 hours using the LSAM gantry router machine. The tool datum features, and removal of interim members, were machined prior to removal from the bead-board. The Thermwood LSAM machine offers the ability to machine and 3D print on a single platform. The composite cure tool mold line part surface achieved at surface profile tolerance of .020” (+/-.010”).

Machining the Composite Cure Tool on Thermwood LSAM

Machining the Composite Cure Tool on Thermwood LSAM

The Boeing Research and Technology (BR&T) laboratory performed functional testing on the LFAM composite cure tool to ensure vacuum integrity and dimensional stability requirements were reached. The LFAM tool performed as expected and achieved all requirements. Several composite parts were fabricated from the tool. The tool durability was assessed during the multiple autoclave cure cycles and fabricated (3) composite parts. The tool maintained dimensional stability and vacuum integrity throughout the functional testing and composite part manufacturing.

LFAM tool after Autoclave Cure

LFAM tool after Autoclave Cure

The composite cure tool was printed and NC machined on Thermwood’s Large Scale Additive Manufacturing (LSAM) 1020 machine. The LFAM technology cost savings was estimated at 50% compared to traditional tool fabrication methods, and reduced tool fabrication lead-time by 65%. The cost savings and tool fabrication cycle time reduction could provide enormous benefit to any organizations performing low volume or custom composite part fabrication and repair.

Composite Part Fabricated from LFAM Tool

Composite part fabricated from LFAM tool

Nondestructive Inspection (NDI) was performed on the composite parts fabricated on LSAM tools. The NDI results did not indicate any porosity. Due to the complex shape of the composite demonstration part several NDI process were employed. X-ray and C-Scan results did not reveal any delaminations or defects.

The Bottom Line

The program benefited from a cooperative effort among several contributors to achieve success. The partnership between industrial technology leaders, Boeing and Thermwood coupled with the Office of Naval Research’s drive to transition technology, led to the successful program. “Collaborations such as this help expand the scope of capabilities of emerging large scale additive technology by addressing real world challenges that would be difficult for any single entity to define and address by itself. We look forward to new challenges moving forward”, says Thermwood CEO, Ken Susnjara.

Additional development is key to expand LFAM composite cure tooling implementation. Boeing Associate Technical Fellow Michael Matlack commented “The program provided significant results in validating additive manufacturing as a viable method of producing lower cost, capable tooling with substantial time savings over traditional methods.”

LSAM Info Request

Thermwood to Demonstrate the Versatile CabinetShop 43 510-8 and the Powerful Cut Ready Cut Center at AWFS 2021

Posted by Duane Marrett on Fri, Jun 25, 2021

Tags: Thermwood, Announcements, Trade Shows, AWFS, Cut Center, CutReady, 2021, CabinetShop 43

AWFS Fair 2021

For AWFS 2021, Thermwood Corporation, an innovator in the design and manufacture of 3 and 5 Axis CNC Routers, is proud to demonstrate two systems. We’ll have our versatile and affordable CabinetShop 43 510-8 and our powerful Cut Ready Cut Center machining on site.

Cabinetshop 43

CabinetShop 43 510-8

We will be machining plastic sheets, signs, outdoor furniture and nested based applications on our CabinetShop 43 510-8 CNC Router. This machine features a 5'x10' base with a 5'x8' table, allowing it to offer 21 tooling positions with its automatic bar style tool changer. It also has an improved dual pipe dust collection system, programmable pop-up pins, auto tool length measurement and an automatic lubrication system. This configuration is also available as a 512-10, with a 10 foot table on a 12 foot base. Auto labeling and an unload rake system for nested based production are also available as an option. 


Cut Ready Cut Center

Cut Ready Cut CenterThermwood will also be demonstrating the award-winning Cut Ready Cut Center. This powerful system helps you quickly and easily create most products a cabinet shop would want to make without a CNC programmer (cabinets, furniture, doors, drawers, moldings, stair stringers and much more). Just tell it what you want to make via a simple touch-screen interface, and it makes it. Or, you can operate it as a traditional CNC router.  

Most people can operate it with little or no training or guidance. It is complete, fully contained with all the ancillary equipment smoothly integrated into a package that almost runs itself.


Check us out in Booth #1701

CabinetShop 43 510-8We'll be demonstrating live on both machines during the show, as well as operating an eCabinet Systems kiosk.  Our eCabinet Systems expert will be designing nested-based applications on the fly to send to the CabinetShop 43 to be machined.  In addition to our Cut Center live demonstrations, we will also have two Cut Ready kiosks, where you can explore the software and see just how easy it is to design most things a cabinet shop would want to make. 

Please visit our booth (#1701) and speak to a Thermwood representative to learn more about these two powerful and affordable additions to any shop!


What are the Differences Between a Cut Center and a CNC Router?

Cut Center Intro Final Rev_1.0

Take a Tour of the Cut Ready Cut Center

Cut Center Components Walk Around Final Rev_2_0_trimmed.m4v

How to Design a Cabinet and Add it to the Job in Cut Ready

Cut Center Cabinet Selection Final Rev_1_0

Learn How Simple it is to Machine a Cabinet Job on the Cut Ready Cut Center

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Exploring Cut Ready's Leveling Feature

Cut Ready Leveling

Cut Center Info Request

Thermwood 2021 Scholarship Recipients

Posted by Duane Marrett on Fri, Jun 18, 2021

Tags: Thermwood, Announcements, Scholarship, 2021

Thermwood is proud to announce that we will be awarding three scholarships to dependents of associates for the Class of 2021. Each recipient will receive a $2,000 renewable scholarship. 

Since the introduction of these renewable scholarships, Thermwood has awarded over $200,000 to students wishing to further their education. 

Leah O'Brien

Leah O'Brien is the daughter of Jennifer and Chris O'Brien of Stendal, IN.  She is a graduate of Southridge High School. 

She has been involved in FCA, Natural Helpers, SHS Choir, Yearbook and St. Mary's Youth group.  She was also a member of the Swim, Cross Country and Track teams. 

Leah plans to attend Ivy Tech Community College in the fall to study Visual Communications.

 

 

Aiden Susnjara

Aiden Susnjara is the son of April and Jason Susnjara of Santa Claus, IN.  He is a Summa Cum Laude graduate of Heritage Hills High School. 

He has been a member of Beta Club as well as the Basketball, Tennis and Golf teams.  Aiden has also been involved with Riley's Dance Marathon.  

Aiden plans to attend Purdue University in the fall to study Engineering. 

 

 



Kylee VaalKylee Vaal is the daughter of Courtney and Scott Vaal of Jasper, IN.    She is a graduate of Jasper High School. 

She has been involved in FCA, Octagon Club and SADD.  She is also a volunteer for the Redemption Church Kids Ministry.  Kylee was also part of the Soccer, Basketball and Unified Track teams.  

Kylee plans to attend the University of Southern Indiana to study Biology.

 

 

Thermwood would like to congratulate all seniors of the Class of 2021 and wish them the very best in their future studies and endeavors!