The United States Air Force Research Laboratory (AFRL) Manufacturing and Industrial Technology Division (ManTech) is interested in large scale polymer-based additively manufactured (AM) composite cure tooling. Boeing submitted an idea to ManTech’s Open BAA to evaluate the current state of additive manufacturing technology with respect to the fabrication of low cost autoclave capable tools for the production of composite aerospace components. The initial demo tool is for an AFRL concept aircraft fuselage skin (Figure 1). Boeing contracted Thermwood to demonstrate capability of their Large Scale Additive Manufacturing (LSAM) machine.  

Figure 1: Air Force Research Laboratory Conceptual Aircraft & Full-Scale Tool

Please click below for video

The Thermwood LSAM machine offers an innovative additive manufacturing machine capability with its Vertical Layer Printing (VLP). The vertical layer printing AM process provides a significant cost benefit by increasing the size components can be printed, thus reducing assembly cost for large tools. To validate the VLP process using high temperature autoclave-capable materials, Boeing and AFRL chose to 3D print a section of the large tool to evaluate the LSAM functionality. The Mid-Scale tool was printed on Thermwood’s LSAM  Additive Manufacturing Demonstration machine in Southern Indiana using a 40mm print core running 25% carbon fiber reinforced Polyethersulfone (PESU).

More Information on LSAM

LSAM is based on exciting new technology developed from an entirely new direction.

LSAM is intended for industrial production. It is not a lab, evaluation or demonstration machine, but is instead a full-fledged industrial additive manufacturing system intended for the production of large scale components.

Thermwood has already applied for 19 separate patents on various aspects of this new technology (several have already been granted and more will be coming as development continues). LSAM is truly “state of the art” in this exciting new world of Large Scale Additive Manufacturing. 

The Secret to LSAM Print Quality...A Different Process

Santa Ana, CA - July 2019 – Ascent Aerospace, a leading provider of aerospace tooling systems, factory automation and integration solutions, is excited to announce its recent investment of a Large Scale Additive Manufacturing (LSAM) machine from Thermwood Corporation, a technology leader and manufacturer of CNC and 3D printing equipment based in Dale, IN.

With a 10’ x 40’ fabrication area, Ascent’s LSAM machine will be the largest available in the aerospace market, allowing for both the printing and machining of a wide range of thermoplastic composite materials.

The use of 3D printing in the aerospace tooling sector has continued to mature over the last several years and is accelerating in usage; with this, Ascent Aerospace plans to answer the industry's call and take additive technology to a new level by leveraging its deep expertise in tooling to commercialize production ready additive solutions. As a new tooling option for its customers, Ascent intends to utilize the LSAM machine to bring tools such as layup molds, masters, trimming/drilling fixtures and vacuum holding fixtures to market faster than ever before. The LSAM machine will be co-located with Ascent's composite tooling shop, autoclave and clean room in Santa Ana, California, and will allow Ascent to build targeted tools lighter and more efficiently, providing time and cost savings to its global customers.

The LSAM machine will have an industry leading build area, providing aerospace customers the opportunity to benefit from large-scale printed composite tooling. By combining this technology with Ascent's in-house tooling expertise and heritage engineering, it will be possible to fabricate and deliver fully functional select fixtures and molds with significantly reduced lead-times of a traditional metallic tool. The wide variety of materials that are compatible with the LSAM, such as ABS, Polycarbonate, Nylon, and PESU resins with reinforcing compounds, will further expand the selection of tooling solutions that Ascent will bring to the market. 

Michael Mahfet, the CEO of Ascent Aerospace, stated, "Our investment in the LSAM represents the next milestone in Ascent's multi-year technology roadmap and realization of expansive efforts studying the benefits of additive manufacturing within the aerospace tooling market. This capability positions us to remain the leader in new and innovative tooling solutions, supporting strong collaboration with our customers and supplementing our in-house, vertically integrated design and fabrication capabilities."

Ascent Aerospace is committed to challenging the industry norms, improving manufacturing processes and providing customers with the best solutions to meet their demands.

About Ascent Aerospace

Ascent Aerospace is a world renowned, single-source provider of production and automated assembly systems for the aerospace and defense industry. As the largest tooling group in the industry, Ascent produces a full suite of both mold and assembly tooling required for the aerospace manufacturing market, including the largest Invar molds ever made for aerospace.  As an automation provider and production system integrator, Ascent works with customers to develop their project and see it through from process engineering, to build and installation to ensure it is an efficient and cost effective solution. Visit www.ascentaerospace.com for more information.

More Information on LSAM

LSAM is based on exciting new technology developed from an entirely new direction.

LSAM is intended for industrial production. It is not a lab, evaluation or demonstration machine, but is instead a full-fledged industrial additive manufacturing system intended for the production of large scale components.

Much of the technology used in Thermwood’s LSAM machines and print process is completely new. Thermwood has already received numerous patents on these revolutionary developments and many more are in the works. In addition to the projects already announced, many other exciting results that LSAM has already achieved are covered by non-disclosure agreements and must be kept secret. LSAM is truly state-of-the-art in the exciting new world of large scale additive manufacturing.

The Secret to LSAM Print Quality...A Different Process

The 2019 AWFS Show (July 17th-20th) promises to be an exciting opportunity to visit Las Vegas and see the very latest technology from Thermwood!  Like the award winning Thermwood CUT CENTER (make virtually anything a cabinet shop would want to make - with no programming) and the powerful and versatile MODEL 45 with a pod system (machining solid wood, plastic and aluminum).

This year, Thermwood is proud to demonstrate the award-winning CUT READY CUT CENTER (with Artie inside to help you quickly and easily create most products a cabinet shop would want to make without a CNC programmer).  

You'll have the opportunity to see just how easy it is to run this powerful machine.  Just tell it what you want, and it makes it...it is that easy! 

We'll be demonstrating live during the show, and you can be part of it by helping to operate the CUT CENTER.  Please visit our booth (#7425) and speak to a Thermwood representative to get your hands on this exciting machine!

CUT READY Series With Artie Inside

Despite the cute name, Artie is actually a cutting edge, artificial intelligence engine inside the CUT READY control.

You tell him what you want and he creates a program to make it. These are not pre-programmed libraries. No part programs exist in the control until Artie creates them. This is nothing less than a bold next step in the evolution of the CNC router.

Artie is already capable of programming tens of millions of unique products and is constantly learning how to make and do more and more new things. Artie is easy enough that virtually anyone can work with him with little or no training.

Solid Wood Machining on the Thermwood MODEL 45

We will also be demonstrating solid wood, plastics and aluminum utilizing a pod system and a horizontal aggregate on the Thermwood MODEL 45.

The heavy-duty MODEL 45 is designed for a variety of functions including the machining of rotary operations when equipped with our optional C-Axis. This expands the capability of this already useful machine to include volutes, carvings, chair parts, stair components and much more.  The MODEL 45 is also equipped with smart-router technology that helps save labor and material, are easy to use and will make you a lot more money than ordinary routers.

See in operation at  AWFS 2019!

Both the CUT CENTER and the MODEL 45 will be on display and cutting live at AWFS 2019 (Thermwood booth #7425).  We will also have several displays featuring the powerful new Combination Cabinets (this new tool allows you to easily create a large bank of connected cabinets with multiple sections). 

Using Combination Cabinets can bring real savings to your production - Cut Ready Combination Cabinets can save you time, material and money!

Make plans to see this exciting new technology in person and attend AWFS 2019  (July 17th-20th) at the Las Vegas Convention Center - Las Vegas, NV or contact us at 800-533-6901 for more information.

The  Cut Ready Combination Cabinets feature allows you to easily create a large bank of connected cabinets with multiple sections. 

These combination cabinets can be created with or without face frames, and you can also customize each of the sections (width and style).  Choose from many different options for these sections from one or two doors, with/without drawers, false fronts, open sections, slotted areas for storage and much more. 

Check out the video below to see this new feature in action.

Visit AWFS 2019 and try out the Cut Center for yourself!

See just how easy it is to use the Cut Center

The Thermwood Cut Center will be in action during AWFS 2019.  You'll have the opportunity to see just how easy it is to run this amazing machine.  Just tell it what you want, and it makes it...it is that easy! 

We'll be demonstrating live during the show, and you can be part of it by helping to operate the Cut Center.  Please visit our booth (#7425) and speak to a Thermwood representative to get your hands on this exciting machine! Make plans now to visit us and see this exciting technology in person! 

Solid Wood Machining on the Thermwood Model 45

We will also be demonstrating solid wood, plastics and aluminum utilizing a pod system and a horizontal aggregate on our Thermwood Model 45. 

The heavy-duty Model 45 is designed for a variety of functions including the machining of rotary operations when equipped with our optional C-Axis.  This expands the capability of this already useful machine to include volutes, carvings, chair parts, stair components in addition to cabinets, solid wood, millwork, phenolic, display fixtures and much more.  This high-performance three axis CNC router is available in either single or dual spindles, multiple table sizes and many other options as well.

Thermwood Model 45 Videos (including machining HDPE plastic sheets):

See at AWFS 2019:

Both of these machines will be on display and cutting live at AWFS 2019 (July 17th-20th) in Booth #7425 at the Las Vegas Convention Center.  Make plans now to visit us and see this exciting technology in person! 

What Some of Our Cut Center Customers Are Saying...

The Thermwood Cut Center is all about saving you time and money, using an easy to operate and sophisticated combination of software and machinery that you can feel confident in.  

We've taken the fear out of automation by combining our easy to use interface and years of experience in the industry to create a powerful tool that will allow you to focus more on your products, business, making money, and worry less about being intimidated by the technical details. Your time is money, and the Cut Center helps you save more of both.

Below, find out just what makes the Thermwood Cut Center so special and profitable:

1. Huge Product Line From Day One

The product offering on the Thermwood Cut Center is extensive, and constantly growing.  It includes cabinets, closets, furniture, doors, drawers, moldings and much more, and the sizes can easily be changed with no programming.

With a Cut Center, you can:

• Make your products with little effort
• Make your competitors products with little effort
• Expand your current offering to other profitable products with little effort
• Profit from an ever-expanding product line with no programming

We can also help you develop custom libraries for your specific product(s) in the size range and material you want and install them in your machine.   

2. Virtually Instant Start Up

It is likely you will be in full production with a Thermwood Cut Center in about a half a day.

A typical CNC router can take as much as six months to program and get to that point. A half a day or a half a year? There is serious cost associated with that half a year. 

With the Cut Center, it is all figured out for you, and from Day One you get:

• No programming
• No extensive training required
• No tooling to figure out and buy
• No cutting parameters to figure out 

3. Feel Confident That the Details are Taken Care Of

The Thermwood Cut Center is engineered and programmed by experts who have taken all of the worry and headaches out of the equation.  This gives you the confidence and peace of mind to focus on what is important - making money!   You can concentrate on your product (its configuration, material and dimensions), as well as marketing and growing your business. 

All the technical knowledge needed to make the machine work is already in place and invisible to the user - no new technical skills are necessary. You simply select what you want to make, right at the machine, and it makes it.

Running a Cut Center is much easier than a typical CNC router:

• It manages tools for you
  • Figures out which tools to use for each job
  • Figures out proper cutting speeds
  • Tracks tool life
• It recovers from problems easily and smoothly
  • Easily remake damaged parts by simply scanning a label
  • Recover from broken tool(s) without scrapping parts
  • Easily recut a defective sheet
• It manages maintenance
  • It tells you when to clean filters
  • It tells you when to lubricate
  • It easily connects you to a service tech if you ever need more help 

4. Constant Updates and Additions

We are constantly adding new libraries, features and capabilities to the Award-Winning Cut Ready Cut Center.  

For instance, our latest update ads:

• Over 1,200 new cabinet definitions
• Varying depths for Shaker door styles
• The ability to easily share off-fall between Cut Ready and CNC Mode
• Expanded update Information easily accessible in Cut Ready
• Expanded images and descriptions

5.  Also Operate As a CNC Router 

You can also operate the Cut Center system as a CNC router in the traditional manner, running programs generated with virtually any CNC software. 

It is simple to switch between operating as a CNC router and operating as a Cut Center to assure that all machine parameters are properly reset and that the standard Cut Center tooling is properly installed, checked and ready to run. 

6. No Programming Required with Artie Inside

Cut Ready doesn’t need a programmer because there is already one inside the control. We call him “Artie”.

Despite the cute name, Artie is actually a cutting edge, artificial intelligence engine inside the Cut Ready control. You tell him what you want and he creates a program to make it. These are not pre-programmed libraries. No part programs exist in the control until Artie creates them. This is nothing less than a bold next step in the evolution of the CNC router.

Artie is already capable of programming tens of millions of unique products and is constantly learning how to make and do more and more new things. Artie is easy enough that virtually anyone can work with him with little or no training.

7. With Other CNC Routers - Programming Required?

Every CNC router, regardless of price, has one thing in common..it must be programmed. You will need a CNC programmer.  You will also need an operator with knowledge of tooling, feed speeds and holddown.  

This programming and operating knowledge takes a lot of time and experience to master. That can be time away from running your machine and making money.   

8. Other CNC Routers - Not So Cheap After All

A typical CNC programmer will cost you more each month than the payment on a Thermwood Cut Center, which does not need CNC programs or CNC programmers.

So, even if a machine was FREE, it would still cost you more than a Thermwood Cut Center, and in a few years the Cut Center payments go away while your programmer costs most likely will go up. 

When you consider everything, a cheap router isn’t so cheap after all. In fact, some CNC router manufacturers will charge 3-5 times more for spare parts and service.

In these cases, the manufacturers plan is to double or triple their profit over 5 years through spare parts and service.  This is why the initial cost of the CNC router is cheaper.

10. Absolute Commitment to Your Success

Thermwood is committed to you and your success.  We want you to love your new Cut Center, and for it to help move your business to the next level.  

We have the best service and support in the business, and help is available with a push of a button on your Cut Center.  We also have free phone, email and forum support.   In addition, we are available to help you create custom libraries for your projects to quickly get you going.   

11. Powerful Testimonials From Our Customers...

---

---

The video below shows the powerful Cut Ready 43 machining a door and matching drawer front in MDF using diamond tooling. 

Cut Ready 43 Door and Drawer Front Video

More Info on the Cut Ready 43 with Artie Inside

The Cut Ready 43 shown above is equipped with a 5 by 8 table, a 21-position tool changer and a high flow vacuum hold-down system (additional table sizes and options are available).

The Cut Ready 43 is intended to bring the magic of Artie to a lower priced system. It features a full-sized vacuum table and, just like its big brother, doesn’t require a CNC programmer. Just like a Cut Center, it can help you quickly and easily create most products a cabinet shop would want to make without a CNC programmer (only operational training is required).

Since this is a CNC router at its core, you are free to program and operate it as a normal CNC router if you want, but the magic of Artie makes the Cut Ready 43 a whole new exciting experience!

For More Info on the Cut Ready 43, please click here.

Learn More about Artie 

Cut Ready doesn't need a programmer because there is already one inside the control. We call him "Artie".

Despite the cute name, Artie is actually a cutting edge, artificial intelligence engine inside the Cut Ready control. 

He is the first A.I. dedicated to making your manufacturing life easier to handle.  While he is a CNC programmer and designer at heart, he also watches over your shoulder to make sure everything goes smoothly and efficiently. 

You tell him what you want and he creates a program to make it. Be it cabinets, doors, moldings or furniture, Artie will program it for you! 

These are not pre-programmed libraries. No part programs exist in the control until Artie creates them.  He is already capable of programming tens of millions of unique products and is constantly learning how to make and do more and more new things. Artie is easy enough that virtually anyone can work with him with little or no training. For more on Artie, click here.

Thermwood is proud to announce Audrey Jones and Mackenzie Tullis as our scholarship recipients for the Class of 2019.  Each 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. 

Audrey Jones is the daughter of Amie and Carl Jones of Ferdinand, IN.  She is a graduate of Forest Park High School. She has been involved in Community Impact, Student Council 9^th and 10^th grade, Key Club, 4H, and Golf. 

While at Forest Park she has received most improved Sophomore in Band, State Runner Up in Band, and MVP in Golf for 2 years. 

This fall Audrey will be attending IUPUI to study Clinical Lab Science.

.

Mackenzie Tullis is the daughter of Mark and Melanie Tullis of Lincoln City, IN. She is a graduate of Heritage Hills High School.  She has been a member of Patriot Vibe. 

Mackenzie will be studying Dental Hygiene at the University of Southern Indiana.

Thermwood would like to congratulate all seniors of the Class of 2019 and wish them the very best in their future studies and endeavors! 

Dimensional Innovations now has Kansas City’s biggest 3-D printer

Overland Park-based Dimensional Innovations unveiled its newest piece of equipment, a $2.2 million 3-D printer and five-axis router that can make items 10 feet wide, 20 feet long and 5 feet high.

Produced by Thermwood, the equipment is known as a Large Scale Additive Manufacturing (LSAM) machine. It can produce huge components from reinforced thermoplastic composite materials. It’s the only one of its kind in the Kansas City area and one of only a handful currently in use in the U.S.

“Within the design, architecture and construction space, we’re not aware of anyone else who has this capability,” Dimensional Innovations CEO Tucker Trotter said. “There is not really someone else we can look to for examples on how to use this equipment, so we’re going to have to define that. It puts pressure on our team because there aren’t answers yet, but it also opens up incredible opportunities.”

Trotter said the purchase of the LSAM was driven by a secret project DI isn't allowed to discuss at this time, for production of a large-scale, iconic element. It had limitations on weight, needed to be prefabricated so it could be assembled in the field, had to be strong enough to meet wind load and had fire-proofing requirements.

“I went into the discussion for this project thinking it was really not a good fit for us,” Trotter said. “I couldn’t see how we could do it. But the culture at DI is so cool that we had people here who didn’t take no for an answer and spoke up saying they thought we could do it and here’s how. It started as a crazy idea, but now that we’ve got this equipment, I think it’s really going to advance who we are and how we’re seen by a lot of people.”

The company's growth made the addition possible. DI's business had outgrown its headquarters at 3421 Merriam Drive in Overland Park, so it moved the sign fabrication business to a new shop at 15500 W. 108th St. in Lenexa. That created room at the headquarters, allowing the company to buy the LSAM. It also is allowing DI to start building out about 50 new offices inside the headquarters, creating room to hire more designers and sales people.

DI has also been expanding into other cities, opening offices in Atlanta, Minneapolis and, most recently, Los Angeles.

“The smaller satellite offices have been low risk, and they’ve been very successful,” Trotter said. “We like that and will continue to do that. It puts our people and brainpower closer to projects.”

It also helps the company attract more talent, which in turn leads to more work.

About Dimensional Innovations

Dimensional Innovations - Dimensional Innovations is an award-winning, multi-disciplinary firm that creates dynamic, engaging and interactive solutions that bring brands to life.  DI helps businesses develop exceptional brand experiences to captivate and engage their target market. Works with clients that include 50,000 seat stadiums and history museums to create experiences customers will love. Focuses on the sports, corporate, student life and entertainment industries.

More Information on LSAM

LSAM is based on exciting new technology developed from an entirely new direction.

LSAM is intended for industrial production. It is not a lab, evaluation or demonstration machine, but is instead a full-fledged industrial additive manufacturing system intended for the production of large scale components.

Much of the technology used in Thermwood’s LSAM machines and print process is completely new. Thermwood has already received numerous patents on these revolutionary developments and many more are in the works. In addition to the projects already announced, many other exciting results that LSAM has already achieved are covered by non-disclosure agreements and must be kept secret. LSAM is truly state-of-the-art in the exciting new world of large scale additive manufacturing.

The Secret to LSAM Print Quality...A Different Process

Cut Ready - The First CNC That Doesn't Need a Programmer!

Cut Ready doesn’t need a programmer because there is already one inside the control. We call him “Artie”.

Despite the cute name, Artie is actually a cutting edge, artificial intelligence engine inside the Cut Ready control. You tell him what you want and he creates a program to make it. 

Artie has actually been hiding out behind the scenes in the Cut Ready control this whole time, but he has never made an appearance until now. He is the first A.I. dedicated to making your manufacturing life easier to handle.  While he is a CNC programmer and designer at heart, he also watches over your shoulder to make sure everything goes smoothly and efficiently. 

You tell him what you want and he creates a program to make it. Whether it is cabinets, doors, moldings or furniture, Artie will program it for you! 

These are not pre-programmed libraries. No part programs exist in the control until Artie creates them. 
He is already capable of programming tens of millions of unique products and is constantly learning how to make and do more and more new things.

Artie is easy enough that virtually anyone can work with him with little or no training. 
 

Cut Ready is currently available on two machines from Thermwood:

The Cut Center - requires neither a CNC programmer nor a trained machine operator. Artie moves beyond just programming to guide the operator through the entire production process real time. It is complete, fully contained with all the ancillary equipment smoothly integrated into a package that almost runs itself.  Pretty much anyone can run a Cut Center.

The Cut Ready 43 - is a lower-priced machine that doesn’t need a CNC programmer, but does require a trained and somewhat skilled machine operator.  With the Cut Ready 43 system, Artie offers help during the production process, but not quite to the extent that it does with a Cut Center.  

Cut Ready Series Machines Detailed Comparison 

More Info on the Cut Ready 43 with Artie Inside

The Cut Ready 43 is equipped with a 5 by 8 table, a 21-position tool changer and a high flow vacuum hold-down system (additional table sizes and options are available).

The Cut Ready 43 is intended to bring the magic of Artie to a lower-priced system. It features a full-sized vacuum table and, just like its big brother, doesn’t require a CNC programmer. Just like a Cut Center, it can help you quickly and easily create most products a cabinet shop would want to make without a CNC programmer (only operational training is required).

Since this is a CNC router at its core, you are free to program and operate it as a normal CNC router if you want, but the magic of Artie makes the Cut Ready 43 a whole new exciting experience!

For More Info on the Cut Ready 43, please click here.

The video below shows the powerful Cut Ready 43 machining a door and matching drawer front in MDF using diamond tooling. 

More Info on the Cut Center with Artie Inside

The Thermwood Cut Center is equipped with a 5'x10' table, easy sheet flipper, vacuum cups and a host of other software and equipment.  It is all designed to help you save time and money, using an easy to operate and sophisticated combination of software and machinery that you can feel confident in.  

We've taken the fear out of automation by combining our easy to use interface and years of experience in the industry to create a powerful tool that will allow you to focus more on your products, business, making money, and worry less about being intimidated by the technical details. It is complete, fully contained with all the ancillary equipment smoothly integrated into a package that almost runs itself.

The Cut Center is the ultimate in next generation CNC. 

Your time is money, and the Cut Center helps you save more of both.

For More Info on the Cut Center, please click here.

What Some of Our Cut Center Customers Are Saying...

The Thermwood Multi-Purpose 45 is a heavy-duty, high-performance three axis CNC router designed for real-world production.

Available in either single or dual spindles (with optional rotary axis), the Model 45 is used in the machining of composites, tooling boards, plastic sheets, aluminum, cabinets, solid wood, millwork, phenolic, display fixtures, nested based panels and much more.  

This versatile machine is available in a variety of table sizes and has enough standard features and options to get the job done.

Features of the Model 45:

• 12 HP HSD Spindle (3,000-24,000 RPM). Optional 18 HP Spindle
• 4 Position Bar Style Automatic Tool Changer. Optional 7 Position
• Optional Rotary Axis (accepts stock from 8" (200mm) in diameter and up to 56" (1.4m) in length)
• Fixed Steel High Flow Table with Moving Gantry (sizes from 5'x5' to 7'x12')
• Multi-Function Table (pod system capable) (Optional)
• At the Head Automatic Tool Changer (Optional)
• Extended Z Clearance and Stroke (Optional)
• Optional Pod System Available
• Optional Pause Mats Available
• Automatic Lubrication (optional)
• Automatic Tool Length Measurement (Optional)
• Three-Dimensional Laser Compensated Axis Alignment
• Control Nesting
• Siemens Intelligent Servo Drives Throughout
• QCore SuperControl
• Machine Training and Installation
• Free Lifetime Phone/Forum Support

Videos