Thermwood has released a Vertical Layer Printing (VLP) option for its LSAM (Large Scale Additive Manufacturing) machines. This option allows parts to be printed which are as long as the machine table itself.

It does this by adding a second moving table, mounted perpendicular to the main fixed horizontal table. As layers are printed, this vertical table moves after each layer is printed, growing the part along the length of the machine rather than growing it upward. Thermwood’s “controlled cooling” print technology minimizes sag, which might otherwise pose a serious problem if the part were kept at an elevated temperature, as is common with traditional thermoplastic composite printing.

VLP Example Video

12 Foot Long ABS Trim Fixture for Boeing 777x Aircraft

As previously announced, one of the initial parts printed with this system is a 12 foot long, carbon fiber reinforced ABS trim fixture for use in the production of the Boeing 777X aircraft.

VLP More Info

During development, Thermwood has vertically printed and validated the use of a variety of polymers, including high temperature materials such as PSU, PESU and PEI with good results. It appears that parts printed using VLP are structurally and functionally identical to parts printed in the traditional horizontal layer orientation.

This means that, just as with traditional horizontally printed LSAM parts, molds and tools printed using VLP maintain vacuum in an autoclave to aerospace standards right from the machine, without the need for any type of external coating.

Versatile Vertical Layer Printing

During VLP printing, the growing part rides on Teflon coated stainless steel belts. The belts and table drives (which can be fitted to any LSAM that is at least 20 feet long), have been designed to process parts which weigh up to fifty thousand pounds. Thermwood believes that this is more than adequate for anything customers are considering today.

Print Long Parts in One Piece with VLP

The main advantage of Vertical Layer Printing is that long parts can be printed in one piece.

While it might be faster to print multiple sections of a large part simultaneously, they must then be bonded together so that they can be machined as a single piece. There are some disadvantages to this approach:

• It requires time, labor and effort to machine mating surfaces, glue them together and wait for the adhesive to completely cure.
• It may also require more than one bonding session for a larger part which typically requires more time and effort than simply printing the part in one piece.
• Also, gluing printed parts together generally only works for certain room temperature or low temperature polymers.
• Higher temperature materials are generally chemically and solvent resistant enough that they don’t bond well enough for autoclave use. This means if you want to 3D print a really large autoclave tool using a high temperature polymer, printing it in one piece is the only real option. Thermwood’s VLP now makes this both feasible and practical.

Quick Change from Horizontal to Vertical

VLP has been designed so that the machine can be reconfigured from standard horizontal layer printing to vertical layer printing or back again in a matter of a few hours. It is clear that technology exists, right now today, to 3D print large autoclave capable aerospace tooling on a production basis. Thermwood has already been granted patent protection on key aspects of its Vertical Layer Print technology. 

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

Latest Cut Ready Update Summary

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

Included in this update are enhancements/support to the Cut Ready Publisher:

• The ability to group and run Doors, Drawer Boxes and Cabinet and 1 entire job (rather than 3 separate jobs).
• Additional support for Doors that have been customized by the designer.

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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. 

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Boeing and Thermwood Partner to Demonstrate New 3D Printing Technology

Boeing and Thermwood have employed additive manufacturing technology to produce a large, single-piece tool for the 777X program.  The project is demonstrating that additive manufacturing is ready to produce production quality tooling for the aerospace industry.

Thermwood used a Large Scale Additive Manufacturing (LSAM) machine and newly developed Vertical Layer Print (VLP) 3D printing technology to fabricate the tool as a one-piece print, eliminating the additional cost and schedule required for assembly of multiple 3D printed tooling components. In the joint demonstration program, Thermwood printed and trimmed the 12-foot-long R&D tool at its southern Indiana demonstration lab and delivered it to Boeing in August 2018.

Boeing Research & Technology engineer Michael Matlack believes the use of Thermwood’s additive manufacturing technology in this application provided a significant advantage, saving weeks of time and enabling delivery of the tool before traditional tooling could be fabricated.

The tool was printed as a single piece from 20% carbon fiber reinforced ABS using the Vertical Layer Print system. Boeing purchased a Thermwood LSAM machine with the VLP functionality for the Interiors Responsibility Center (IRC) facility in Everett, Washington.

The ability to quickly produce large-scale tooling at a quality level suitable for a real world production environment represents a significant step in moving additive technology from the laboratory to the factory floor.

Please click below for video  

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

LSAM Printed PESU Tool is Vacuum Ready Without the Use of Coatings

Thermwood recently printed a tool using PESU (which is a high temp material mixed with 25% carbon fiber) to test for vacuum integrity on an LSAM (Large Scale Additive Manufacturing) system.  After printing and machining the tool, we vacuum bagged it and immediately achieved 28 InHg.  The vacuum line to the bag was then removed, and almost 2 hours later, the vacuum had only dropped 1 InHg to 27 InHg. 

This test result was achieved without the use of any type of external coatings or sealers - the bag was placed directly on the final trimmed surface. 

See this Process in Person at CAMX 2018

Thermwood will have this tool on display to demonstrate this process in our booth (J60) at the upcoming CAMX show held in Dallas, TX on Oct 16^th-18th. 

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

Latest Cut Ready Update Summary

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

Included in this update is the addition of Artie, a new Outdoor Cabinets Library, Publisher improvements and the addition of Lock Dowels.  

Update adds Artie

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, and with this latest update, we flipped on his switch!  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.

New Material Definitions

This update also includes some new material definitions for Artie.  We've given him all the information he needs to know about plastic.  You can now machine anything out of plastic with the knowledge that Artie will program the machine correctly.  Why plastic?...we've also given Artie definitions for another line of cabinets for outdoor use...more info below:

Outdoor Cabinet Library

Specifically designed to withstand the elements, these outdoor cabinets can handle the extreme heat out west, or the salty weather on the coast.  Since they are made from Starboard material, they will last for many years (they are sun-proof, water-proof, and rust-proof), and add style to outdoor living with little to no maintenance.  They also use Cut Ready’s “Slot Slide” technique for drawer boxes.  

While this collection includes typical kitchen cabinet designs, we’ve also added specialty items like countertop cabinets, carts, storage cabinets, cutting boards and cabinets to house a grill…just to name a few.

Outdoor Cabinets with grill and hood installed

Outdoor Cart with Drawer Stack

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Outdoor Grill Base (double door) with false drawer

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Outdoor Storage Closet

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Publisher Updates

The Publisher allows eCabinet users to publish their own designs into Cut Ready.  With this latest update, you can either cut the Doors & Drawer Boxes exactly how you designed them, or choose from the stock Cut Ready versions...and there's a lot to choose from!  Just tell Artie which version of Drawer Boxes or Doors for your design, and let him take it from there!

 

 

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Lock Dowel Cabinet Construction

We are working to keep up with the increase in different cabinet fasteners available in the industry today, and are constantly adding them to Artie's cabinet definitions.  This latest one added is called the Lock Dowel.  For more details on this method, please click here.

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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. 

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The Additive Conference 2018 (September 11th and 12th) in Chicago, IL starts this week, and Thermwood will be there to talk LSAM (Large Scale Additive Manufacturing). 

We will have 3D printed samples to see and  touch as well as videos and literature.  Our knowledgeable sales staff will also be on hand to help answer any questions you may have about the future of Large Scale Additive Manufacturing and how the Thermwood LSAM can help your company charge ahead in this new area. 

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. 

IWF 2018 (August 22nd-25th) starts tomorrow, and we are putting the final touches on our booth (#6735).  What better reason to visit Atlanta, than to see the latest technology and products from Thermwood?  

This year, Thermwood is proud to demonstrate the all new CUT READY 43 and the award-winning CUT CENTER (both help you quickly and easily create most products a cabinet shop would want to make without a CNC programmer), and both with Artie Inside.

You'll have the opportunity to see just how easy it is to run these powerful CUT READY machines. We'll be demonstrating live during the show, and you can be part of it by helping to operate the CUT CENTER and the CUT READY 43!

We will also have two CUT READY kiosks available for attendees to try out the CUT READY software during the show.  Thermwood personnel will be standing by to answer any questions you may have.

CUT READY Series With Artie Inside

Both of these machines in our new CUT READY Series are equipped 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, aluminum and plastic sheet parts on the Thermwood MODEL 45, utilizing a pod system and aggregate tooling.

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  IWF 2018!

The CUT READY 43, the CUT CENTER and the MODEL 45 will all be on display and cutting live at IWF 2018 (Thermwood booth #6735).  We will also have several displays created on the CUT CENTER, as well as some created by our customers, like this outdoor kitchen, designed and machined by Timberwood Properties in Leesburg, FL .

Make plans to see this exciting new technology in person and attend IWF 2018 (August 22nd-25th) at the Georgia World Congress Center - Atlanta, GA., or contact us at 800-533-6901 for more information.

The Secret to LSAM Print Quality… A Different Process

Prior to LSAM, 3D polymer printing was all done using essentially the same approach. Parts were printed with a small print bead onto a hot table, in a heated chamber, keeping the printed part hot until printing was complete.

While this worked reasonably well for smaller net shape parts, scaling the process up for large near-net-shape parts didn’t work quite as well.

A Different Approach

Thermwood took a fundamentally different approach with our LSAM large scale additive manufacturing system. Instead of printing with a small bead in a heated environment, Thermwood uses a large bead, printed at room temperature in an essentially “continuous cooling” process.

The beads are large enough, with enough heat energy, to completely fuse with the previous layer. Thermwood also employs a temperature controlled “compression wheel” to form the round melt coming from the print nozzle into a flattened bead and fuse it with the previous layer.

With this process, print speed is essentially controlled by the cooling rate of the polymer being printed, rather than by the output of the print head. The printed bead must cool enough to support the next layer, but must still be warm enough to fuse completely with it.

This means that there is a specific temperature range, which is different for each polymer, where this approach to printing works. Each polymer requires a certain amount of time to cool to within that temperature range. That amount of time is the fastest that a layer can be printed, regardless of its size.

The output capacity of the print head simply determines how large a layer you can print in the amount of time available for each layer. Thermwood’s standard 40mm melt core can print layer lap lengths of over 200 ft. with most polymers. For even larger parts, Thermwood is working on an even larger melt core which can be retrofitted into the same print head housing as the 40mm core.

This process yields almost perfectly fused structures. Molds printed using the LSAM process routinely hold vacuum at elevated temperature and pressure in an autoclave without the need for any type of external coating.

Unique Part Hold Down Method

The only issue remaining was how to hold the parts during printing. In the previous process, polymer parts tend to stick to a heated table. Since Thermwood’s process doesn’t have a heated table, this wouldn't work. Also, since parts are both printed and trimmed on the same machine with LSAM, the part needed to be held for trimming after it was printed and cooled. Parts generally release from a heated table when they cool down.

LSAM's Patented "Bead Board"

Thermwood’s approach to this requirement turned out to be quite unique. We developed a “bead board” to hold the parts both during printing and trimming.

The beard board consists of a plywood panel to which ABS pellets or “beads” are glued.

When a part is printed with this method, it fuses with the ABS beads holding it to the board, but one additional thing happens. Heat from the printed bead not only heats the ABS beads but also heats the glue holding them.

The glue softens enough that the beads can move on the board as the part cools and shrinks, eliminating cooling stresses that might otherwise be generated by a more rigid system. Once cool, the glue re-hardens holding the part securely for trimming. A couple of large screwdrivers and a hammer will remove the part once it is complete. 

LSAM Printing - Final Thoughts

This print approach required an almost complete rethinking of the print head design, control system operation and software, and we will explore those issues later.

For now, know that LSAM printing, at its very core, is fundamentally different. 

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 over 45 separate patents on various aspects of this new technology (more than half of which 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 2018 IWF Show (August 22nd-25th) promises to be an exciting opportunity to visit Atlanta and see the very latest technology from Thermwood (booth #6735)! 

Like the all new CUT READY 43 and the award-winning CUT CENTER (both help you quickly and easily create most products a cabinet shop would want to make without a CNC programmer) and the heavy-duty MODEL 45 machining solid wood, aluminum and plastic sheet parts.

New CUT READY 43 - With Artie Inside!

Thermwood is proud to introduce our all-new CUT READY 43 (shown above equipped with a 5 by 8 table, optional 21-position tool changer and lift vacuum cups and a standard high flow vacuum hold-down system - additional table sizes and options are available). This machine has many of the features of the CUT CENTER, but at a lower price.

Just like a CUT CENTER, it also can help you quickly and easily create most things a cabinet shop would want to make without a CNC programmer, but unlike the CUT CENTER, it does require a trained and somewhat skilled machine operator. 

The CUT READY 43 will be in action at IWF 2018 in booth #6735.  

Cut Ready Series With Artie Inside

Both of these machines in our new Cut Ready Series are equipped 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.

Try out the award-winning CUT CENTER for yourself at IWF 2018!

The CUT CENTER is the ultimate in next generation CNC routers. It doesn't require programming and 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.

Artie guides you through each step of the production process. If there is anything you don’t understand, he will show you a video of what to do. He manages your tooling and keeps track of routine maintenance. He will show you a video of how to clean filters or top off lubrication. He will turn your vacuum pump on or off as needed and will make sure it is holding properly. Should you encounter a problem he will guide you, step by step, through a solution.

Just like the CUT READY 43, you can operate the CUT CENTER as a traditional CNC router.  However, running with Artie represents a whole new way of operating a machine which must be experienced to be completely understood.  It is just so easy!. The CUT CENTER is the ultimate in next generation CNC.

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 (#6735) and speak to a Thermwood representative to get your hands on this exciting machine! 

Solid Wood Machining on the Thermwood MODEL 45

We will also be demonstrating solid wood, aluminum and plastic sheet parts 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.  

MODEL 45 with Pod System Machining Poplar Hardwood Door:

See in operation at  IWF 2018!

The CUT READY 43, the CUT CENTER and the MODEL 45 (making solid wood, aluminum and plastic sheet parts) will all be on display and cutting live at IWF 2018 (August 22nd-25th) in Thermwood booth #6735 at the Georgia World Congress Center - Atlanta, GA. or contact us at 800-533-6901 for more information.

Make plans now to visit us and see this exciting new technology in person!

New for IWF 2018...

Thermwood Announces an Addition to the CUT READY Family

The CUT READY 43...with Artie Inside!

Thermwood is proud to introduce our all-new CUT READY 43.  This machine has many of the features of the Cut Center, but at a lower price.  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 operation training is required).

Cut Ready Series With Artie Inside

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, and today we flipped on his switch!  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. 

More Details

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). 

See in operation at  IWF 2018!

Make plans now to visit us and see this exciting new technology in person at Thermwood's booth #6735 at the Georgia World Congress Center in Atlanta, GA, or contact us at 800-533-6901 for more information.

This is nothing less than a bold next step in the evolution of the CNC router!