Latest Cut Ready Update Summary

We are constantly adding new features and abilities to the Award-Winning Cut Ready Cut Center

With this latest update, we've added over 1,200 additional cabinet definitions, updated many cabinet images and expanded the information presented with the cabinet, added an informational Update section to Cut Ready, added varying depths to Shaker Doors and incorporated the ability for users to share left over off-fall between Cut Ready and CNC Mode. 

Over 1,200 Cabinet Definitions Added

Thermwood has added over 1,200 new cabinet definitions to Cut Ready, giving Artie (Cut Ready's A.I.) the ability to make a wider range of cabinet styles!  This batch of definitions focus on kitchen base cabinets for both frameless & face frame choices. Below are a few examples: 

Updated Images and Descriptions

We’ve also replaced lots of cabinet images to make choosing a cabinet easier, while also including valuable information:

Expanded Update Information

Finding out what is in each update just got easier, too.  Simply select the information button to learn what is in each update.

Varying Depths for Shaker Doors

Shaker Doors now have varying depths to choose from:

Easily Share Off-Fall Between Cut Ready and CNC Mode

Advanced users who currently switch between Cut Ready and CNC Mode can now easily share your left-over off-fall between the two modes.

About the Cut Center

The Thermwood Cut Center is an exciting alternative to traditional CNC routers for making a wide variety of products including cabinets, closets, furniture, doors, drawers and much more.  Just tell the machine what you what to make and it does it...it is that simple!  NO programming is required. 

---

 

A joint venture program between Thermwood and Bell has pushed the limits of 3D printing, resulting in what Thermwood believes is the largest 3D printed autoclave capable tool ever made. 

The first half of an 18 foot helicopter blade mold that was 3D Printed in just over 3 hours

A common limiting factor within aerospace development programs is expensive, long-lead time tooling.  Bell, not being satisfied abiding by the industry norms, decided to reach out to Thermwood to help solve this challenge.

Video

The Challenge

Shortly after initial conversations with Bell, the Thermwood team offered an opportunity of a partnership centering around the capabilities of their new 60mm melt core technology.  The original challenge for quickly and affordably manufacturing large bond tooling seemed closer to reality than ever before. 

Bell responded to this opportunity in kind by providing Thermwood a model of a closed cavity blade mold measuring approximately 20 feet long, 14 inches wide and 17 inches high. 

The basic tooling requirements were as follows:

• Must to be printed in one continuous run for vacuum integrity
• Surface finish must be 32 RMS or better
• Tooling must be able to withstand 90 psi at 360°F. 
• Tight tolerances and features were also required to ensure proper mating of the two blade mold halves.

The Process

Upon receiving the model and requirements, the Thermwood team sprang into action. Utilizing their new 60mm melt core technology, they began to print the tool using TechmerPM’s 25% Carbon Fiber reinforced PESU (Polyethersulfone) in one continuous run. Working closely with Thermwood, Techmer has formulated this material specifically for LSAM additive printing.

The printable material has a Glass Transition Temperature of over 400°F and can easily survive common aerospace component cure cycles of up to 360°F, at 90psi. The combination of Techmer's new materials and Thermwood's printing technology, resulted in a print time of one tool half in just 3 hours 8 minutes and an “as printed” weight of 542 pounds.

Thermwood technicians claim the Techmer PESU material prints as easily as ABS, although at a much higher temperature, allowing quality autoclave-capable molds to be made from the high temperature polymer.

This extraordinary achievement was made possible by a new, larger melt core recently installed on Thermwood’s LSAM system at its Development/Demonstration Lab in Southern Indiana. The standard LSAM machine print head housing can be equipped with different capacity melt cores, each offering different minimum and maximum throughputs.

Continuous Cooling Print Process

With Thermwood’s room temperature “Continuous Cooling” print process, the cycle time for each layer is determined solely by how long it takes a particular printed polymer to cool to the proper temperature to accept the next layer.

Only by printing at the proper temperature can you achieve a totally fused, void-free printed structure that will maintain vacuum in an autoclave without a coating. The print head output determines how much material can be printed during the time it takes for the layer to cool. Bigger print heads mean larger parts, not necessarily faster layer to layer print time.

Thermographic view of the part being printed

The new 60mm melt core has a measured maximum output of 480 to 570 pounds per hour depending on the polymer being printed and can print over 100 feet of typical print bead (.830” x .200”) per minute. This high print rate, even when processing high temperature material, allows the print bead to be oriented along the length of the tool. This is desirable for Bell, who manufactures large composite parts, because thermal expansion is significantly lower in that direction, minimizing expansion and contraction of the tool with temperature changes.

Internal Printed Support Structure

Another interesting feature of this tool is that the internal printed structure supports the mold without actually contacting or touching the back side of the mold cavity. This means air can flow freely under the entire formed part in the autoclave, making the part curing process easier and more consistent. The ability to incorporate a complex internal design, such as this, is another major advantage of using additive manufacturing for this type of tooling.

3D printed internal support structures

Thermwood’s LSAM Print ^3D slicing software specifically supports programming of involved internal structures such as these.

Internal support structures in  LSAM Print ^3D slicing software

Bell Investigates Multiple Manufacturing Processes

Bell is continuing to investigate integrated technologies that support multiple manufacturing processes and tools.  The LSAM is capable of supporting printing processes as well as trim and drill processes to meet aerospace specifications.  Once printed, the team began to machine the bond tool half by utilizing the other aspect of the LSAM system.  The total machining time of the lower blade mold half was 40 hours.  

The completed bond tool was able to maintain Bell’s vacuum standards required for autoclave processing right from the machine, without the need for a seal coating. 

Part maintaining vacuum during extended testing

The part steadily holding vacuum during testing

Next Steps

The Thermwood team will print the second half of the blade mold, with the intention of having Bell cure a full molded blade within the final additively-manufactured bond tool, another first.  Further testing will be completed by both Thermwood and Bell teams on PESU printed molds, to continue innovating in this space. 

Final Thoughts

Thermwood believes recent LSAM technology advances such as Vertical Layer Printing and Changeable Melt Cores (coupled with polymers specially tailored for LSAM processing), are opening exciting new possibilities for additive production of even larger and more technically complex components.

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.

LSAM is the Leader in Large Scale Additive Sales

In the last year, Thermwood's LSAM additive manufacturing systems were the clear market leaders in the sale of large scale 3D printing systems for thermoplastic composite materials, selling virtually all systems in the US during the year.

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

Latest Cut Ready Update Summary

We are constantly adding new features and abilities to the Award-Winning Cut Ready Cut Center

With this latest update, we've added greater flexibility to Face Frame Bath Cabinets.  You now have more control when resizing these cabinets.  In addition, we've added several more, unique Bathroom cabinets as well.

New Bathroom Cabinet Additions Examples:

About the Cut Center

The Thermwood Cut Center is an exciting alternative to traditional CNC routers for making a wide variety of products including cabinets, closets, furniture, doors, drawers and much more.  Just tell the machine what you what to make and it does it...it is that simple!  NO programming is required. 

---

 

TAHOE Boats, Springfield, MO. formally announced the all-new, revolutionary T16 boat design, engineered with families in mind. Using innovative technology, the T16 delivers an unprecedented lightweight design and affordability with an uncompromising commitment to quality and performance.

One factor that made this boat possible is that the T16 was designed and built in the U.S. leveraging innovative Thermwood LSAM techniques never before used in the marine industry.

White River Marine Group, the marine manufacturing arm of Bass Pro Shops, worked with Thermwood, utilizing Thermwood’s Large Scale Additive Manufacturing (LSAM) system and the latest in LSAM technology to custom-print the tool used to manufacture the boat’s hull – the first time 3D printing has been used on actual boat production at this scale.

This boat-building advancement led to greater efficiency in the planning, design and construction of the T16.

The Process

Thermwood printed the master pattern for the boat hull at its Development/Demonstration Labs is Dale, Indiana. The pattern was printed in six sections from 20% carbon fiber filled ABS supplied by Techmer PM, who was an active partner in the program. The joints between the pieces were machined, pinned and bonded together and the assembled hull machined to final size and shape. The entire process required only ten days to complete.

After printing and machining, the tool was sent to White River, where they applied, sanded and polished a proprietary coating, which they developed earlier, using previously printed parts supplied by Thermwood.

Prior to this public introduction, Thermwood was able to use images and videos of the process, which have been on our web site for some time now, however, we respected a request not to disclose the participants or final use of the tool until the boat was publicly released by White River Marine Group.

Please Click to View Video of the Entire Process

Current Technology Speeds The Process Up Even More

An interesting note is that this type of tool can be produced in even less time with current technology. Using Thermwood’s Vertical Layer Printing (which wasn’t available at the time this tool was made), this type of pattern can now be printed as one piece in just over two days, eliminating the machining between sections and the bonding process. This should cut build time almost in half.

Master patterns, such as this, are used to make molds for high production rates where multiple molds are required. For larger boats or lower production rates, it may be possible to print the mold itself rather than a pattern from which multiple molds are made. Thermwood has also been working on this approach and has recently announced the successful production of a seven foot long, 1/7 scale model of a yacht hull mold using Vertical Layer Printing. Work continues in both these areas.

Even at this early stage of development it is apparent that large scale additive manufacturing could have a dramatic, perhaps even a transformational impact on production methods used in the marine industry, significantly reducing tooling cost and dramatically speeding up the tool building process.

About TAHOE Boats

TAHOE is part of the White River Marine Group family of brands, Bass Pro’s marine manufacturing arm and the largest builder of boats in the world by volume. In addition to TAHOE, White River Marine manufactures America’s favorite boat brands including MAKO, NITRO, RANGER, REGENCY SUN TRACKER, TRACKER, TRITON and others. All White River Marine boats are proudly manufactured in the U.S.

About Techmer PM

Techmer PM is a leading materials design company and works in deep partnership with plastics processors, OEMs, and designers to solve some of their most difficult business, manufacturing, and sustainability challenges. For more than 30 years, they have helped consumer and industrial product manufacturers achieve the finest color, texture, appearance, and functional enhancements for a variety of product applications. Techmer PM is a family-owned company that’s based in Clinton, Tennessee where they operate their largest production facility, as well as five others throughout the U.S. They have been a pioneer in developing polymers for large scale additive manufacturing applications.

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

Latest Cut Ready Update Summary

We are constantly adding new features and abilities to the Award-Winning Cut Ready Cut Center

With this latest update, we've expanded the options when choosing a grain matching style for cabinets.  The interface has been simplified and expanded to allow you to pick multiple directions for the grain matching on your cabinets.

Expanded Grain Matching 

About the Cut Center

The Thermwood Cut Center is an exciting alternative to traditional CNC routers for making a wide variety of products including cabinets, closets, furniture, doors, drawers and much more.  Just tell the machine what you what to make and it does it...it is that simple!  NO programming is required. 

---

 

Thermwood has completed initial testing of a larger melt core for its LSAM (Large Scale Additive Manufacturing) systems and the results are stunning.

Print up to 570 pounds per hour

Thermwood’s additive print head housing can accommodate interchangeable melt cores.  A melt core consists of a feed housing, extruder and polymer melt pump and determines just how fast material can be printed.

The standard 40mm melt core has a maximum output of between 190 and 210 pounds per hour, depending on the polymer being printed, which translates to 40 - 50 feet of standard bead (0.83”x0.20”) per minute.

The new 60mm melt core has been tested with different polymers and has achieved print rates from 480 to 570 pounds per hour, which translates to well over 100 feet of bead per minute.

More Info

With Thermwood’s room temperature “Continuous Cooling” print process, the cycle time for each layer is determined solely by how long it takes a particular printed polymer to cool to the proper temperature to accept the next layer.

Only by printing when the previously printed layer is within the proper temperature range can you achieve a completely solid, void free printed structure that maintains vacuum in an autoclave without a secondary coating. This is as fast as you can print a layer.

The print head output then determines how much material can be printed during the time it takes for the layer to cool. Bigger print heads mean bigger parts not faster layer to layer print time.

“This new development opens a new world of additive manufacturing possibilities” says Thermwood’s Founder, Chairman and CEO, Ken Susnjara. “This is one of the most exciting advances we have achieved to date and now we can do things we couldn’t even consider before”.

New Possibilities

For example, Thermwood recently announced Vertical Layer Printing which allows parts to be printed that are as long as the machine table. In this process, however, the layer stack direction is along the length of the part. This works well for room temperature or low temperature patterns, fixtures and molds, however, for high temperature molds, for use in an autoclave for example, the thermal expansion (CTE) along the stack direction is as much as 20 times greater than along the bead direction. Therefore, it is desirable to print long tools with the bead oriented in the long direction, however, print heads, even Thermwood’s 200 pound per hour head, currently the largest in the industry, have been too slow for this…until now.

The high print rate of the new melt core, even when processing high temperature materials, allows the print bead to be oriented along the length of the tool, even for tools that are as long as the machine table itself.

Melt Core Changeover in One Shift

In addition to a maximum speed, each melt core has a minimum speed at which it can continuously print. Parts with bead lengths smaller than this minimum, require the print head to move to a “Hot Hold” area where it runs at a slow maintenance speed, spilling material at a slow rate until the required cooling time has been achieved. This wastes material and means the larger melt core may not be desirable for all applications. Many tools and molds are just too small for efficient printing with the larger core.

If a user needs both small and large parts on the same machine, the melt cores can be switched in less than a shift.

Final Thoughts

Thermwood believes the next step in this development is to address the challenge of really long autoclave capable tooling. Be assured, work in this area has already begun.

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

Thermwood has already 3D printed a full size pattern which was used to produce production sport boat hull molds. Much larger vessels, yachts for example, require a different approach. In these instances, it is desirable to print the mold itself rather than print a plug or pattern from which a mold is made.

Working with an undisclosed marine industry collaborator, Thermwood has printed a scale model of such a hull mold to test and validate the process.

Video

Printing The Mold Itself - No Plug/Pattern Necessary

The 1/7^th scale test mold for this project is approximately seven feet long (the full size hull is approximately 50 foot). It was printed from 20% carbon fiber filled ABS using Thermwood’s LSAM additive manufacturing machine.

Six separate pieces of different lengths, the longest two, each being over seven feet long, were printed concurrently using LSAM’s Vertical Layer Print capability. Printing required about 30 1/2 hours.

The ability to simultaneously print multiple parts of variable heights highlights the flexibility of both the vertical print process as well as Thermwood’s LSAM Print^3D slicing software. The parts were then trimmed on the same machine and assembled into two mold halves.

More Details

The tool includes a deep undercut at the transom, so the finished mold needs to be two pieces, split down the middle. These mold halves are clamped together for layup and then separated to remove the finished hull after curing.

Molds for hulls of longer than fifty feet will be printed in multiple sections, assembled for hull layup and then disassembled to remove the finished part. The test tool printed here simulates that assembly and disassembly process.

The tool printed in this program will be tested using production materials in a production environment. Thermwood continues to work on methods and techniques needed to refine this into a production ready process.

Thermwood believes that the marine industry will benefit significantly from emerging large scale additive manufacturing technology and that this project is a significant first step toward the direct production of large vessel tooling.

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