LSAM Research Lab at Purdue Enables CERN Particle Collider Upgrade Prototyping

Posted by Duane Marrett on Tue, Apr 12, 2022

Tags: Thermwood, Announcements, Purdue, Thermwood LSAM, Thermwood LSAM Research Laboratory

Purdue CMSC, in collaboration with Purdue Silicon Detector Laboratory (PSDL), is designing, prototyping, testing, and fabricating composite support structures for CERN’s Large Hadron Collider (LHC) CMS and ATLAS experiments. This is part of the particle collider’s High Luminosity upgrade, with installation of final components in 2026-27. The Thermwood LSAM 105 Additive Printer and five-axis LSAM Trim router at the Purdue LSAM Research Laboratory have enabled rapid large-scale printing and machining of trimming fixtures for the high precision composite tube structures. The 1m long, 208mm radius trimming fixture was printed on the LSAM with Acrylonitrile Butadiene Styrene (ABS) reinforced with 20% by weight of carbon fiber.

Thermwood LSAM Research Laboratory at Purdue University

This 914mm long prototype of the CMS upgrade inner tracker support tube will allow project partners at national labs, universities around the world, and CERN to begin installation tests of their structural and detection components. Individual components installed into this support tube are expected to be positioned within +/- 0.5mm or less, so accurate machining of interface features is critical. This kind of precision at large scale is made possible, economical, and convenient with the aid of systems like LSAM.

Printing Details

Printing Details

Since critical surfaces would be machined later, and to increase production speed for the prismatic geometry, the tool was split into two vertically-printed segments. The halves were bonded with adhesive and dowel pins for joint strength and stability.

Printing Details - closer look

Machining Details

The faces that would become the trimming fixture base were machined to the flatness required for fixturing later. The printed, bonded fixture was then mounted on pedestals in the LSAM Additive Trimmer and the surface was machined to fit the nominal inner surface shape of the composites half-cylinders to be trimmed. Edge finding and reference features were machined into the trimming fixture to allow proper centering of the cured composite part.

Printing detail - closeup

Using this printed and machined fixture, the composite part edges were trimmed, interface holes drilled, mating surfaces machined flat and a scarf joint for joining the two half cylinders was created. The precision trimmed composite halves were then able to be bonded together.

Machining on the LSAM Trim

LSAM Trim Machining - closeup

Final Result

The final tube, 3.2m long, has to support 140kg of mass while only allowing sub millimeter deflections to occur. Purdue CMSC and PSDL will also be designing, fabricating, or testing other composite support structures for the CERN LHC upgrade as small as 0.5mm sheet goods and as large as 2.4m x 5m sandwich panel tubes. It is planned for the LSAM system to be utilized to create tooling and some final components for these other structures.

Finished result! 

About CMSC

The Composites Manufacturing and Simulation Center (CMSC) of the College of Engineering and the Purdue Polytechnic are located in over 30,000 square feet of the Indiana Manufacturing Institute building. CMSC consists of faculty experts in composites manufacturing, a professional staff of doctoral degree engineers, a support staff and research students in doctoral, masters and bachelor’s degree programs of the Schools Aeronautics and Astronautics, Chemical Engineering and Materials Engineering, as well as, the Department of Aviation Technology in the Polytechnic.

LSAM RESEARCH LAB AT PURDUE UNIVERSITY CMSC

A comprehensive set of laboratories is available at the IMI for the study of composites manufacturing processes, characterization of composite materials, and the validation of simulation software essential to development and verification of the digital twin concepts in composite manufacture and performance. Focus specialties include extrusion deposition additive manufacturing, composites autoclave processing of continuous fiber systems, compression and injection molding of discontinuous fiber composites, prepreg impregnation, infusion molding, sheet forming, complex mold-forming and hybrid continuous/discontinuous fiber systems. Workflow simulations are being developed to provide for end-to-end digital twins of these manufacturing processes. Accordingly, manufacturing informed performance predictions are a direct outcome of these workflow analyses.

About Thermwood Corporation

Thermwood Corporate HeadquartersThermwood is a US based, multinational, diversified CNC machinery manufacturer that markets its products and services through offices in 11 countries. Thermwood is the oldest manufacturer of highly flexible 3 & 5 axis high-speed machining centers known as CNC routers.

Thermwood has also become the technology and market leader in large scale additive manufacturing systems for thermoplastic composite molds, tooling, patterns and parts with its line of LSAM (Large Scale Additive Manufacturing) machines that both 3D print and trim on the same machine. These are some of the largest and most capable additive manufacturing systems ever produced and are marketed to major companies in the aerospace, marine, automotive and foundry industries as well as military, government and defense contractors.

 

Meet the All New AutoProcessor 43

Posted by Duane Marrett on Wed, Mar 09, 2022

Tags: Thermwood, New, 3 Axis, Announcements, cabinets, nested based, Furniture, AutoProcessor, AutoProcessor 43

Thermwood's AutoProcessor 43 Machining Center is an all-new complete, nested-based, CNC routing system for machining cabinet boxes, custom furniture and basically any nested type of sheet product.

Thermwood AutoProcessor 43

 

HubSpot Video

AutoProcessor 43

The AutoProcessor 43 is fully automatic from labeling and positioning of the sheets, to machining and off-loading the machined parts.

With each cycle, the machine simultaneously and automatically:

  1. Labels each part area on the sheet
  2. Moves and automatically positions the sheet on the table
  3. Machines the material while labeling the next sheet
  4. Simultaneously off-loads the finished parts and reloads the next sheet
  5. Continuously repeats the process

Standard Features

The AutoProcessor 43 is loaded with Standard Features and Optionsap_43_composite_2022.fw

  • 5'x10' (1.5m x 3.0m) Fixed Table
  • Moving Gantry
  • 10 Position Automatic Rotary Tool Change System
  • 12 HP (9kw) ISO Electro Spindle
  • High-Flow Vacuum Table
  • Automatic 6000 LB Lift Table for Loading
  • Simultaneous Automatic Labeling System
  • Automatic Dust Extraction During the Unload Raking Process
  • Automatic Pop Up Pins
  • Automatic Tool Length Sensor
  • Automatic Lubrication System
  • Automatic Sheet Load/Unload System
  • Automatic Sheet Positioning System
  • Siemens Intelligent Servo Drives Throughout
  • 3D Laser Compensated Axis Alignment
  • SuperControl
  • Control Nesting
  • 5 Spindle Drill Bank (Optional)
  • Unload Sorting Table (Optional)
  • Touch Screen Control (Optional)
  • Made in America

Well Equipped with Features/Options

12 HP Spindle

12 HP (9KW) SPINDLE

A direct driven spindle with a speed range up to 24,000 RPM.  the High Frequency Spindle is cooled with an electric fan for quieter running and contains ceramic bearings for longer life and for less maintenance.  The 12 HP (9kw) spindle provides the user with a heavy duty, precision spindle for high performance and reliability.  Standard

 

 

 

10 Position Rotary Automatic Tool Changer

ROTARY AUTOMATIC TOOL CHANGER

10 Position Rotary Automatic Tool Changer Includes (10) ISO-30 Tool Holders and collets.  Max tool size is 2" (50mm) in diameter and 3.25" (83mm) in length.  Standard (optional HSK63F)

 

 

AUTOMATIC CNC LABELER SYSTEM

AUTOMATIC CNC LABELER SYSTEM

The Automatic CNC Labeler System labels the sheet before the machining operation.  The labels assist with sorting and assembling finished parts.  Optional

 

 

Automatic Load/Unload System

AUTOMATIC LOAD/UNLOAD SYSTEM

Automatically loads sheets up to 60" x 120" (1.5m x 3.0m) to assist operator with unloading the machine and automatically position the sheet.  Each individual sheet is elevated and positioned by a series of programmable vacuum cups.  A steel rake is mounted in front of the router motor and travels with the machine gantry allowing parts to be removed off the front of the table.  Dust extraction/table sweep occurs during the rake process.  Standard

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FIVE SPINDLE DRILL BANK

The drill unit is a vertical boring head with five vertical spindles.  The spindles are on 32mm centers.  The drill unit can be independent.  Optional

 

Vaccum Pump

VACUUM PUMP

Universal Vacuum System is a unique method for holding panels to the table top for machining.  A sheet of MDF is used as a work surface on the top of the table.  The high flow pump vacuums through the work surface, holding the part to the table.  Pumps are available in different sizes.  Optional

About Thermwood Corporation

Thermwood Corporate HeadquartersThermwood is a US based, multinational, diversified CNC machinery manufacturer that markets its products and services through offices in 11 countries. Thermwood is the oldest manufacturer of highly flexible 3 & 5 axis high-speed machining centers known as CNC routers.

Thermwood has also become the technology and market leader in large scale additive manufacturing systems for thermoplastic composite molds, tooling, patterns and parts with its line of LSAM (Large Scale Additive Manufacturing) machines that both 3D print and trim on the same machine. These are some of the largest and most capable additive manufacturing systems ever produced and are marketed to major companies in the aerospace, marine, automotive and foundry industries as well as military, government and defense contractors.

Thermwood Announces Promotions

Posted by Duane Marrett on Tue, Feb 01, 2022

Tags: Thermwood, Announcements, Employees, Promotions

Thermwood, who has been producing CNC routers for over 52 years has announced several promotions for long-time employees.  Please join us in congratulating these gentlemen and welcoming them to their new positions!  

Thermwood Promotes Jim Bullis to Vice President of Sales

Jim Bullis - Vice President of Sales

We are pleased to announce the promotion of Jim Bullis to the Vice President of Sales position. In his new role, Jim will oversee the sales and operations of the Machining Products Division at Thermwood. 

Jim is a long-standing employee with over 26 years of experience at Thermwood. He has held numerous positions, initially starting as a Field Service Technician to Trade Show Manager and over the last 19 years as an Account Manager.

Jim resides in Southern Indiana with his wife, Jessy and children.

 

Thermwood Promotes Brendan Haas to Account Manager

Brendan Haas - Account Manager

We are pleased to announce the promotion of Brendan Haas to an Account Manager position within the Machining Products Division. In his new role, he will be responsible for sales and dealer relationships over his designated areas, which is approximately half of the US.

Brendan initially started at Thermwood as a Field Service Technician, and over the last three years, as an Upgrade Specialist in the Retrofit Department for Technical Services.

Brendan and his wife, Kateland reside in Holland, IN. 

 

Thermwood Promotes Pete Riddle to Upgrade Services Specialist

Pete Riddle - Upgrade Services Specialist

We are pleased to announce the promotion of Pete Riddle to Upgrade Service Specialist in the Retrofit Department. In his new role, Pete will be responsible for sales of upgrades, retrofits, refurbished machines and the Advanced Support Program.

Pete is a long-standing employee with approximately 21 years of experience at Thermwood. He has held numerous positions, initially as a Field Service Technician and then as Programming Support and for the last 11 years as Training Instructor.

Pete and his wife, Susan reside in southern Indiana.


About Thermwood Corporation

Thermwood Corporate HeadquartersThermwood is a US based, multinational, diversified CNC machinery manufacturer that markets its products and services through offices in 11 countries. Thermwood is the oldest manufacturer of highly flexible 3 & 5 axis high-speed machining centers known as CNC routers.

Thermwood has also become the technology and market leader in large scale additive manufacturing systems for thermoplastic composite molds, tooling, patterns and parts with its line of LSAM (Large Scale Additive Manufacturing) machines that both 3D print and trim on the same machine. These are some of the largest and most capable additive manufacturing systems ever produced and are marketed to major companies in the aerospace, marine, automotive and foundry industries as well as military, government and defense contractors.

Thermwood Honors Retiree Denny Palmer For His Years of Service

Posted by Duane Marrett on Fri, Jan 28, 2022

Tags: Thermwood, Thanks, Retirement

Thermwood thanked Denny Palmer, Vice President of Sales, with a luncheon today to celebrate his 37 plus years of service with the company. 

Have fun in your next chapter, Denny!

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President David Hildenbrand thanking Denny.

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Congratulations Denny on your retirement!

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Denny with his son Eric, daughter Kate and her husband and family. 

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Denny with (l-r) International Account Manager Mike Iubelt, Account Manager Brent East, Sales Coordinator Twilan Moore, Account Manager Jim Bullis and Demonstration Technician Matt Seger.

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Thermwood employees enjoying a lunch in Denny's honor.

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Thermwood employees enjoying a lunch in Denny's honor.

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Denny with his plaque made by Deer Creek Customs

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Denny and Executive VP Jason Susnjara

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Denny and Account Manager, Jim Bullis

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Denny saying goodbye to Jimmy Glenn

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Denny saying goodbye to Gordon Wright

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Classic Denny Expression!

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21 Reasons Thermwood LSAM Dominates Large Format Additive

Posted by Duane Marrett on Tue, Jan 18, 2022

Tags: Thermwood, Announcements, Thermwood LSAM, Patented, VLP, ALP, HLP, Compression Wheel

Virtually all, if not all, large format, FDM additive systems, sold to industry in the last several years have been Thermwood LSAMs.

Watch the video below to learn 21 reasons why:

 

HubSpot Video

 

LSAM Info Request

Thermwood Receives 32 Additive Manufacturing Patents as an Early Christmas Gift

Posted by Duane Marrett on Tue, Jan 04, 2022

Tags: Thermwood, Announcements, Local Motors, Thermwood LSAM, Patented, Boeing, Navair, Al Davis Torch, General Atomics

Thermwood routinely applies for patent protection on additive manufacturing technology it develops for its LSAM large format additive systems. During COVID, we received electronic copies of patents that were granted, however, the official hard copies were withheld.

A couple of days before Christmas 2021, we received a package containing the official hard copy of 32 additive manufacturing patents. This was certainly a one-day record for Thermwood and a welcome sight!

Thermwood Receives 32 Additive Manufacturing Patents

In addition to these latest patents, Thermwood already has a large portfolio of earlier issued patents covering the unique, large format (5x10 foot table and larger) 3D print technology it has developed. This LSAM technology is currently the most widely used large scale additive print technology operating in industry today. It’s used in a wide variety of industries including aerospace, transportation, heavy equipment, foundry and large decorative structures. It is being used to produce a diversity of products including aerospace patterns, molds and tooling, heavy equipment foundry patterns, bus chassis, large valve body foundry patterns and trim tooling. It was even used to print the tallest 3D printed structure in the world, the 92 foot tall Al Davis Memorial Torch at Allegiant stadium in Las Vegas.

Al Davis Memorial Torch Printed on Thermwood LSAM

Thermwood offers this unique patented technology on a wide variety of equipment, the largest, most diverse product offering of its kind available today. It includes a broad selection of machines, including single and dual gantry, fixed and moving table configurations, with both print-only and print-and-trim systems, from 5 by 10 foot to 20 by 60 foot print envelopes. We are working on even larger machines but that’s for another day.LSAM offers the broadest line of large scale additive systems available in the market today

Boeing Navair project

The primary focus of the patented LSAM technology is to reliably and repeatedly produce the highest quality, best fused, most homogeneous printed structures possible from a variety of reinforced thermoplastic polymer composites including those intended to operate at elevated temperatures. Although it is nice to have been granted these patents, it is even nicer to finally have the official hard copies in hand.

LSAM Info Request

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

HubSpot 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

HubSpot Video

 

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

HubSpot Video

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


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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.

HubSpot Video