What Do You Get With a Thermwood Machine?

When you purchase a CNC router from Thermwood, you get a superior machine, a superior control, superior performance and the best service and support in the business.  Our CNC Experts work with you during every step of the process to insure that you receive the optimum machine configuration for your specific application, and that you gain the knowledge and assistance you need to get into production as quickly as possible.  

You are never on your own with a Thermwood machine, and help is always free for the life of the machine!  Below, we'll go into more detail on each step of the Thermwood Total Solution process:

Thermwood Model 90 5 Axis 5'x12' Dual Table CNC router

Customize Your Solution

Thermwood's Total Solution means that we can customize your machine operation to suit your specific needs.  Our experienced program techs can create new programs or modify your existing programs, work with you on fixturing and tooling, create custom interfaces for your control and much more.  

Because we are a single-source manufacturer, we can easily modify and hone any part of the machine or control to fit your exact need.  Our ultimate goal is to provide the best solution possible with the lowest learning curve for you. We'll stay by your side during each step of the way. We also provide phone, email and forum support, always free of charge.

Thermwood Customers IDL Worldwide with their new Model 45 CNC router

Support When You Need It

Our Total Solution also means that support doesn't stop with the sale.  We are by your side during your five-day training course at our state-of-the-art factory as well as during installation at your facility. During installation, you are paired with a dedicated CNC Expert to work with you one-on-one at your facility to answer any programming and operation questions you may have.  Their goal is to make sure your Thermwood CNC machine gets into production as quickly as possible and running at its optimum performance. 

Thermwood Customers learning programming skills during our five-day training class

The Thermwood Total Solution:

Training and Production Support

• In-Depth Machine Training at our state-of-the-art facility
• Production Start-Up Assistance at your facility with a dedicated CNC Expert
• Help from our CNC Experts when you need it via phone/email/forum 

Customizing Your Solution

• Customizable Control Interface (we can create a custom control interface just for you)
• Customizeable Machine Operation (modify/create new programs and/or machine hardware)
• Fixturing and Tooling Assistance 

Better Machines

• High-Performance, Highly Reliable Siemens Drives Throughout
• Full Function, High Performance CNC Control (future-proofed with an upgrade path)
• Designed using State of the Art CAD/CAM
• Weldments Fully Stress-Relieved
• Three-Dimensional Laser Compensated

More Features

• Mobile App - track the operation of your Thermwood CNC router(s) and the programs that run on them from anywhere by using your cell phone, PC or other mobile device
• Extensive Software Capability (control accepts output and can even combine files from a wide variety of design software)
• Automatic Tool Management (manages tooling and tool life - not easy without this feature)
• Maintenance Tracking (manages lubrication and routine maintenance based on actual machine use)
• Error Reporting (graphically displays location of error and suggests remedy)
• Maintenance Videos (on-screen videos guide you through adjustment and repair)
• Dynamic CAD Drawings (view and explode every machine assembly on the control screen)
• Dynamic On-Screen Manuals (view and search the machine manual from the control screen)

Better Service and Support

• Free Phone/Forum/Email Support
• Virtual Service (instantly address virtually anything a service visit can - fast)
• Free Ongoing Control Updates (not available from others - you're stuck with what you have)
• Quick Tech Service Visits Directly from the Factory When Needed (single source responsibility)
• Extensive Spare Parts Inventory with Overnight Shipping

The Bottom Line:

Our systems install fast, start up quick, are easier to use and maintain, produce more and last longer.  The Thermwood Total Solution means that we work with you before you buy, after you buy and into the future to make sure you get the best performance and financial benefit from your Thermwood machine.

Thermwood CNC machines are used across a wide variety of Industries.  One Thermwood Customer – Universal Plastics and Mayfield Plastics - are involved in the thermoforming of plastic materials.

Since Universal Plastics was founded in 1965, they have been a leader in the thermoforming industry.

The Universal plant has over 95,000 square feet and over 80 employees.  As Universal Plastics has grown, they have refined and further developed the thermoforming process to allow the manufacture of large and complex products that could never have been conceived in the previous generation. Today’s thermoformed products can match the quality and finish of injection molding, in high performance plastics, and in sizes that dwarf the capabilities of most molders.

Universal utilizes Thermwood CNC machines for trimming of complex thermoformed parts as well as producing thermoforming tooling.  In fact, Universal and Mayfield Plastics have purchased 10 Thermwood C67 machines in the last seven years.

Thermoforming tooling can be built from wood, composite, cast aluminum, or machined aluminum billet. Temporary molds are commonly built of wood or composites, which can be easily machined. Permanent tools are either machined or cast aluminum, depending on the depth of the tool. Thermoforming tools can be modified easily, so changes can be made quickly and for much less money than the hardened steel tooling typical of molded parts.  For this reason alone, thermoforming is often the better process if your design hasn’t been solidified.

Universal believes quality parts are a direct result of quality tools, and take great pride in making quality machined or cast aluminum tools that deliver consistent quality products year after year. Our 5 full time toolmakers have a combined 100 years’ experience in tool and fixture making and they build many of tools in-house.

Mold makers use cast aluminum molds for larger quantities production. Aluminum molds are designed by CAD designers.  Once designed, these mold designs are transferred to Thermwood CNC routers that produce the patterns required for the final mold.

Also of note, the Western Mass Chapter of the National Tooling and Machining Association conduct several tours of member companies each year to give the membership a view of the diversity of the companies that do machining.  About 25 members of the WMNTMA visited Universal in February for a tour of their facility and in particular, to review the mold making and machining capabilities. Universal produces about 30% of their tooling and the balance is purchased from tool vendors around the country and area.

The Western Mass chapter has machine shops as well as vendors to the machining industry in their membership.

The all new Cut Ready Cut Center is available for free live demonstrations here at our modern factory headquarters in Dale, IN.  During your demo process you can expect:

• The demo process starts with phone consultations with our techs.  This helps us learn about what you want to make, and how the Cut Center can best help improve your operation.
• On the day of the demo, you’ll find a relaxed atmosphere, and receive a complete overview of the easy to use Cut Center and its operation.  You will work with our knowledgeable experts hands-on with this amazing machine.
• By “Hand’s-On”, we mean that you will actually be able to select, size and run product from the Cut Center yourself and see how incredible easy it is to operate.  With no training necessary, you’ll be able to run the Cut Center yourself!
• You’ll get a personalized tour of our modern facility to see our manufacturing process from start to finish, and how we carefully build each machine from the ground up.

Will the Cut Center Make Everything I Want?

We are continually adding products and capabilities to the Cut Center.  But what if something you want to make isn’t in the system yet?  Does that mean the Cut Center won’t work for you? 

Actually, we have developed a program for those who want to make things not already in the Cut Center. How do you get “No Programming” and the simple, intuitive operation of a Cut Center for your special products? With our new “Special Products” program the answer is simple, we add them for you! 

Definitions for your unique products are custom developed and installed in your Cut Center. These are not just CNC programs. Definitions teach your machine to make your products in all their variations, all their sizes, from all the materials you use. If your product requires special fixtures or tooling, we will develop and supply them also. This is a complete, ready-to-run solution. 

Run your products by simply selecting what you want, right at the machine. You can use material of varying thickness and/or adjust product size and features, again, right at the machine. The machine adjusts for all of this with no separate computer, no software and no programming. This is by far the simplest, easiest way to make things. This program is not restricted to cabinets and furniture. It will work for any product that can be manufacturered on a router. 

You can add additional products at any time and can have existing product definitions modified. We stand ready to manage your product offering so you don’t have to. 

With the “Special Products” addition, you still have all the features and product capabilities of the standard Cut Center, with your unique products as an added benefit. 

More Information

To find out more about the Cut Center and the process of adding arranging a free hands-on demonstration, please give us a call at 1-800-533-6901 or click below to fill out an information request form.  We hope to hear from you soon!

Written by Scott Burton - Sales Manager at Royce//Ayr

The latest kitchen design trends are demanding that solid wood and MDF doors appear in the same space with multi-colored cabinet layouts. This reality has challenged door makers to produce MDF doors that resemble solid wood profiles.  Production limitations have traditionally made it impossible to make MDF doors on a CNC router that match solid wood doors made on traditional moulders and tennoners.   

Advancements in MDF door tooling design and related software packages have made it possible to machine MDF doors on a CNC router that could pass as solid wood. A cohesive combination of smart tool design, flexible software, and proper material can produce an MDF product that is almost an exact match to solid wood once the door has been finished and installed. 

The application is possible, but does require some critical tools and design strategy to achieve a door with tight corners and good surface finish that can be primed with minimal sanding.  There are a couple of problems that must be overcome before achieving success.

Shows the current possibilities of MDF profiled doors on a CNC router.  Notice the detailed moldings and small radius on the corners of the inside profile that can be achieved.

Problem # 1 - Moulding details and tight inside corners

In previous years, a simple profile made from a single pass with a profile tool would create a rounded corner affect that made it obvious to the customer that the door was made from MDF and machined from above with a CNC router bit.  Detailed moldings and tight corners were impossible, if not very inefficient to produce.               

Solution # 1

The key to this issue is as much software related as it is tooling, and any solution must include effective communication between tool designers and software programmers.  The obvious solution to create a smaller radius in the corners is to use a smaller diameter tool.  However, this can lead to dramatically increased cycle time which can be prohibitive from a production stand point.  Primitive software made it necessary to have all tools do a complete pass around the door profile, but modern systems allow the smaller diameter tools to isolate all four corners after the larger profile tools have done their work.  The key is to start with a large profile tool to remove the majority of material and then break up the profile into small sections, and design the smallest diameter tool possible to clean the corners.  

It is important to understand the limitations of the smaller diameter tools, and adjust feed rates and RPM accordingly to avoid tool breakage. The smaller diameter tools will often be designed with single flutes, so a drop in feed rate will also ensure better cut quality.  Many small carving tools are better suited to solid carbide or carbide insert, rather than diamond due to design constraints.

Any tool inventory must include larger diameter tools for maximum material removal at higher feed rates, and matching tools with the smallest possible diameter to perform critical detailed carving applications in the corner of inside door profiles. 

Problems # 2 – Surface finish

MDF is generally very consistent and easy to finish on the outside of the panel, but profiling on the inside of the panel can create a surface that is very difficult to finish due to machining lines and “fiber tearout”.   MDF is obviously a porous material that tends to show loose fibers when machined in the core of the board. The density of MDF panel can have a dramatic impact on the resulting cut quality, but regardless of the quality of MDF it is impossible to achieve a surface finish in the core that is equivalent to the outside layer

Flat surfacing on the inside door panels is notoriously difficult as tools tend to leave machining lines on the overlapping tool path.  Depending on the fiber size in the core, tools can also pull fibers which creates a pitted affect that must be filled by primmer.  If fibers are not sheared off, they tend to raise up during priming, resulting in additional sanding or priming required.

Solution # 2

There are some machine parameter adjustments that can be made to improve surface finish.  Smaller chiploads will obviously provide less feathering of fibers, but excessively small chiploads will cause heat generation and reduced tool life, so feed rate reduction is not always ideal.  The solution lies in the tool design and cutting edge geometry.   

Shows an example of a diamond surfacing tool designed to provide premium surface finish on MDF door panels.  Notice the “Integrated” tool holder and tool body, which ensures optimal performance and allows tool to remove material at higher feed rates without sacrificing cut quality

The cutting edge geometry helps limit “overlap lines” between tool passes which reduces the amount of sanding required before priming.   Up shear geometry helps extract large chip loads at higher feed rates to reduce cycle time.  The diamond cutting edge is critical to providing prolonged tool life in difficult surfacing applications that produce excessive heat generation and cutting edge wear.  To achieve optimal results, it is best to run multiple tool passes and leave 3-4 mm for the final finishing pass.

Cabinet doors will always be the focal point of any kitchen, and generally require the most attention to detail.  Proper tooling design and application can help ensure the customer’s expectations are met, but also ensure that production cycle times and finishing costs are controlled.  Consult your tool designers to discover many creative ways to make your MDF doors look as good as wood.  

About Royce//Ayr    

For over 4 decades Royce//Ayr has combined excellent customer service with state of the art cutting tool technology.

Royce//Ayr started out in 1963 as “Royce Carbide Tools Ltd” a small local sharpening shop for woodworking tools. The company soon became involved in the design and manufacture of specialty saw blades and cutters. In the ‘80s and ‘90s Royce started to explore the many possibilities of Insert and PCD-Diamond tooling.

1997 saw the merge of Royce Carbide Tools Ltd. with Ayr Saw & Tool Inc., a manufacturer of HSS saw blades for metal. This merger added valuable experience to the new company Royce//Ayr Cutting Tools Inc. In 2003 the company moved to a new 40,000 sq.ft. facility at 405 Sheldon Drive in Cambridge, ON.

As the industry is constantly changing and looking for better and faster ways to produce their finished products Royce//Ayr is committed to continuously investing in state of the art equipment and highly skilled employees to satisfy the demands placed on them.

Browse through this web site and inform yourself of our capabilities to produce premium quality cutting tools to internationally accepted ISO standards. You can always reach our dedicated sales and engineering staff to help design and develop the best custom tools to meet your specific needs.

With such excellent customer service and quality tooling, it’s no wonder that today Royce//Ayr is a leading manufacturer of cutting tools for wood, plastics, rubber and metal today.

Mission Statement

Royce//Ayr is committed to supplying customers with superior quality tools, excellent customer service and on-time delivery by employing cutting edge technology, tooling and machinery, and experienced dedicated employees.