More Info on the Model 90: https://bit.ly/m90thm

More info on LSAM: https://bit.ly/LSAM_INFO

Live Printing

For CAMX 2022 in Anaheim, CA on October 18^th-20^th, Thermwood will be printing LIVE on an LSAM Additive Printer 510 – two sections of a multi-piece layup tool each day using Airtech Advanced Materials Group Dahltram™ C-250 CF carbon fiber reinforced PC material. LSAM Research Laboratory at Purdue ADDITIVE3D Software will be on display as well, with Purdue representatives on site for demonstrations.  We will also have several large customer-created large scale tools on display from Airtech, Ascent Aerospace, General Atomics and more. 

This promises to be an exciting demonstration of the LSAM Additive Printer Large Scale Additive System in Booth #W2.  

LSAM Research Laboratory at Purdue ADDITIVE3D Software on Display

Representatives from the 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.

We will be printing two sections of a multi-piece layup tool each day using Airtech Advanced Materials Group Dahltram™ C-250 CF carbon fiber reinforced PC material

About the LSAM Additive Printer

The LSAM Additive Printer systems are single gantry, moving table configurations and are available in two table sizes, 5’x5’ and 5’x10’. The 5’x10’ table is available in two configurations, 5’ wide with 10’ of front to back motion and 10’ wide with 5’ of front to back motion. Choice of configuration depends on several factors, fitting it existing factory floor space is one factor.

The specially designed, highly rigid tab and slot, structural steel gantry also incorporates a fume extraction system that pulls print fumes through specially designed activated charcoal filters to remove them and “sweeten” the air.

LSAM additive Printers use the exact same print head mechanism as all the other, including the largest LSAM Systems which means that they produce the same amazing print quality that has made LSAM the leader in large scale additive printing. They also use the same highly advanced Ultra 6 control with all its exclusive, patented print features and capability.

The systems come standard with a single hopper polymer dryer for applications that don’t change print material very often. For installations that print a wider variety of materials, a dual hopper dryer is available as an option.

An enclosure that surrounds the machine is also available. The machine with the full enclosure can also be built to meet European CE standards.

Please Click Here to Register for IWF with 60% off Advanced Registration courtesy of Thermwood, and plan to stop by our booth #B6213 to see our superior technology in action!

For IWF 2022, Thermwood Corporation, an innovator in the design and manufacture of American Made 3 and 5 Axis CNC Routers, is proud to demonstrate three systems. We’ll have our all new AutoProcessor 43 510, our powerful Cut Ready Cut Center and our heavy-duty Model 45 510 machining on site.

AutoProcessor 43

The AutoProcessor 43 5'x10' is an all-new complete, nested-based, CNC routing system for machining cabinet boxes, custom furniture and basically any nested type of sheet product.

It 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

Cut Ready Cut Center

Thermwood will also be demonstrating the award-winning Cut Ready Cut Center. This powerful system helps you quickly and easily create most products a cabinet shop would want to make without a CNC programmer (cabinets, furniture, doors, drawers, moldings, stair stringers and much more). Just tell it what you want to make via a simple touch-screen interface, and it makes it. Or, you can operate it as a traditional CNC router.  

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.  

Super Easy CNC - Make Cabinets, Closets, Doors and Much More!If you build custom cabinets, and want to automate your machining...you really only have two choices. You can do it the easy way…or the hard way.

Designed and engineered in America, the Cut Ready Cut Center is made to simplify and automate your production.

It allows you to remain a cabinet shop, focused on making custom cabinets, instead of a software company, worried about learning difficult and expensive software. 

The Cut Center takes care of both the big and small details so you don't have to!

Making product on the Cut Center requires neither a CNC programmer nor a trained machine operator.   Pretty much anyone can run a Cut Center, and make anything a cabinet shop might need (cabinets, closets, doors, moldings, stair stringers, furniture...and much more)!

Model 45 

We will also be machining solid wood and aluminum and plywood sheet stock on the 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.

Check us out in Booth #B6213

We'll be demonstrating live on all three machines during the show, as well as operating an eCabinet Systems kiosk.  Our eCabinet Systems expert will be designing nested-based applications on the fly to send to be machined.  In addition to our Cut Center live demonstrations, we will also have two Cut Ready kiosks, where you can explore the software and see just how easy it is to design most things a cabinet shop would want to make. 

Please visit our booth (#B6213) and speak to a Thermwood representative to learn more about these powerful and affordable additions to any shop!

For IWF 2022, Thermwood Corporation, an innovator in the design and manufacture of American Made 3 and 5 Axis CNC Routers, is proud to demonstrate three systems. We’ll have our all new AutoProcessor 43 510, our powerful Cut Ready Cut Center and our heavy-duty Model 45 510 machining on site.

AutoProcessor 43

The AutoProcessor 43 5'x10' is an all-new complete, nested-based, CNC routing system for machining cabinet boxes, custom furniture and basically any nested type of sheet product.

It 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

Cut Ready Cut Center

Thermwood will also be demonstrating the award-winning Cut Ready Cut Center. This powerful system helps you quickly and easily create most products a cabinet shop would want to make without a CNC programmer (cabinets, furniture, doors, drawers, moldings, stair stringers and much more). Just tell it what you want to make via a simple touch-screen interface, and it makes it. Or, you can operate it as a traditional CNC router.  

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.  

What are the Differences Between a Cut Center and a CNC Router?

Jody Wilmes (Cut Ready Product Manager) helps you understand the differences between the Cut Center and a regular CNC Router.

Jody provides an in-depth look at what it takes to successfully operate each machine, and lists some of the additional expenses and things to consider when shopping for an automated solution.

Model 45 

We will also be machining solid wood and aluminum and plywood sheet stock on the 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.

Check us out in Booth #B6213

We'll be demonstrating live on all three machines during the show, as well as operating an eCabinet Systems kiosk.  Our eCabinet Systems expert will be designing nested-based applications on the fly to send to be machined.  In addition to our Cut Center live demonstrations, we will also have two Cut Ready kiosks, where you can explore the software and see just how easy it is to design most things a cabinet shop would want to make. 

Please visit our booth (#B6213) and speak to a Thermwood representative to learn more about these powerful and affordable additions to any shop!

Thermwood is proud to announce that we will be awarding four scholarships to dependents of associates for the Class of 2022. Each recipient will receive a $2,000 renewable scholarship. 

Since the introduction of these renewable scholarships, Thermwood has awarded over $200,000 to students wishing to further their education. 

Olivia Lopez is the daughter of Daniel and Tena Lopez of Holland, IN.  She is a graduate of Southridge High School.

She has been a member of the National Honor Society, Business Professionals of America, Freshman Mentor Program, Christian Motorcyclists Association, and tennis team. She is also passionate about creative writing.

Olivia plans to major in Forensic Science at Maryville University in the fall.  

Emma Haefling is the daughter of Paul and Ellen Haefling of Santa Claus, IN.  She is a graduate of Heritage Hills High School.

During high school Emma was part of the Beta Club, Student Council, HH Riley’s Dance Marathon, and Volleyball team. She has been awarded the Top 10% of Class, the Captains & Patriot award for Volleyball, Science Fair awards, and Behavioral Science for 2022 Science Bowl.

She plans to major in Biology (Genetics) at Ball State University this fall.

Andrew Meece is the son of Natalie and Jeff Meece of Huntingburg, IN. He is a graduate of Southridge High School.

He has been a member of the Raider Band and Choir during high school. He is also an active member of the Zoar Methodist Church.

Andrew plans to attend Asbury University to major in Biblical Theology.

Emma Tretter is the daughter of Daniel and Jennifer Vonderheide of Jasper, IN. She is a graduate of Northeast Dubois Jr/Sr High School.

She plans to major in Design Technology at Ivy Tech Community College Evansville in the fall.

Thermwood would like to congratulate all seniors of the Class of 2022 and wish them the very best in their future studies and endeavors! 

THE DETAILS: 

It was determined that carbon fiber filled polycarbonate would provide sufficient strength to withstand the significant forces used in the stretch form process, however unlike traditional lubrication methods, Techmer PM blended a new polycarbonate formulation that contained an internal lubricant in addition to the carbon fiber, eliminating the need for any additional lubrication.

THE PROCESS: 

The tool was printed on Thermwood’s LSAM 1020 dual gantry print and trim system. While this machine is equipped with Vertical Layer Printing and could have printed the tool in one piece, because it requires that you to wait for each printed layer to cool enough before adding the next layer, it would have required 58 hours of continuous print time to produce a one-piece tool. Instead they decided to print the part in four sections, two at a time for a total print time of 29 hour and 20 minutes, cutting the print time in half. Printing required 3,613 pounds of material.

The Four Parts Printed

The four parts then needed to be machined and assembled.

Layout of the Assembly

All surfaces of the parts except for the front working surface were then machined in place.

Initial machining.  The holes in the center of each side are for center-of-gravity brackets used for part handling during assembly.

The mating faces were then machined flat except for slightly raised bosses which insured proper gapping for the adhesive. Adhesive is only one part of a multi part approach used to permanently and securely attach the parts to each other. These are all highly accurate, precision surfaces.

Flat Face has raised bosses to provide proper adhesive gap

PUTTING IT ALL TOGETHER:

Draw bolt holes and slots were machined into the back of the tool which allow the parts to be bolted together in addition to the adhesive.

Machined area for draw bolts

In addition to adhesive and draw bolts, alignment holes and countersink holes were machined into the center sections of the tool.

The 6-inch long alignment pins for these holes are machined with adhesive channels providing not only alignment between parts but also another level of permanent attachment.

Heavy duty alignment pins offer another attachment layer

The next level of attachment uses brackets positioned inside the structure near the front surface, which are attached to each other using tensioned aircraft steel cables, securely holding the front surface of the four parts together.

Brackets with temporary straps which were replaced by tensioned steel cables

The parts were then final assembled using another unique approach. Each part is relatively heavy and because of relatively short open time for the adhesive, there is a limited amount of time available during assembly to apply the adhesive and mate the parts securely together. The parts need to be pushed together while aligned, literally within a few thousandths of an inch and need to be mated absolutely even and square. This turned out to be fairly easy using the Vertical Layer Print table mechanism installed on the LSAM machine.

The parts were carefully hand fitted together. Then, one part was attached to the machine table and the other to the mechanism that moves the vertical table. The vertical table drive then moved the parts apart about 20 inches, adhesive was applied and the vertical table mechanism pushed the parts back together again, square and perfectly aligned.

Adhesive being applied to separated pieces

Draw bolts and cables were permanently attached and after the adhesive fully cured, the completed tool front surface was machined to final dimensions using the LSAM trim head. When Spirit AeroSystems measured the final working surface it was within +/- 0.005”, well within their requirements. Total of all machining including the final working surface was 118 hours and 58 minutes.

THE RESULTS:

Front surface measured to within +/- 0.005"

Spirit AeroSystems then stretched 10 skin panels of 0.050” thick 2024 T3 aluminum to 5% elongation. The press controller showed that each jaw gripping the aluminum sheet had ~100 tons of load on it, so ~200 tons in total. Everything was kept under the same conditions as if running a production part and although the printed tool was considerably lighter in weight than their traditional tools, it appeared to perform in a similar manner.

Skin panel being stretched

THE BOTTOM LINE:

This is a first step. There are additional tests to be performed and more data to be collected, but it does appear that large 3D printed composite stretch form tools can be produced using currently available material and current equipment, saving considerable time and money and opening yet another application for this exciting new technology.

ABOUT SPIRIT AEROSYSTEMS:

Spirit AeroSystems is one of the world's largest manufacturers of aerostructures for commercial airplanes, defense platforms, and business/regional jets.  Also, Spirit serves the aftermarket for commercial and business regional jets.

ABOUT THERMWOOD:

Thermwood is a US based, multinational, diversified machinery manufacturer that has become the technology lead in large scale additive manufacturing of thermoplastic composite molds, tooling, patterns and parts with its line of LSAM (Large Scale Additive Manufacturing) systems that both 3D print and trim on the same machine.  

ABOUT THE LSAM ADDITIVE PRINTER

Thermwood Corporation, manufacturer of some of the largest composite thermoplastic additive manufacturing systems operating in industry today, has announced the availability of a new line of lower cost “print only” LSAM systems, called LSAM Additive Printers.

Thermwood’s current LSAM line of large scale, dual gantry, “print and trim”, near-net-shape additive manufacturing systems use an advanced print technology that produces high quality, fully fused products from a wide variety of reinforced composite thermoplastic polymers, including materials that process at high temperature like PSU, PESU, and PEI.

These systems are being used primarily to produce molds and tooling, most for aerospace and industrial production applications.

SMALL BUT POWERFUL

To accommodate the request for a lower cost system, Thermwood refined and updated the gantry structure of its highly successful 5 axis CNC routers.  This machine was re-engineered to use the incredibly strong “slot and tab” structural steel approach used on flagship LSAM machines. The same table, base structure and servo drives used on their five axis CNC routers could be used pretty much as is. With these changes the “LSAM Additive Printer” was born.

Although smaller than the flagship systems, it is capable of producing large parts at temperatures up to 450° C, with overall size limited primarily by the table size and working envelope. 

Available Sizes

The new LSAM Additive Printers are all fixed gantry, moving table designs with table sizes of 5’x5’ and 5’x10’ and are capable of printing parts up to 4’ high.  The 5’x10’ machines are available in two styles, 5’ wide with 10’ of front to back motion or 10’ wide with 5’ of front to back motion. Maximum table print weight is 1,000 pounds, however, the 10’ wide 5’ deep machine is available with a dual servo drive which doubles the weight carrying capability. It is planned to equip the 5’ wide 10’ deep version with a Vertical Layer Printing option which will allow it to vertically print parts up to ten feet tall.

Trimming Printed Parts

For trimming printed parts, Thermwood recommends our new LSAM Additive Trimmer, which is available in the same table sizes as these new LSAM Additive Printers.  It is available with up to 5’ of vertical travel, allowing it to trim completely around and over the top of the largest part the LSAM Additive Printer can print. As an added benefit, with both an LSAM Additive Printer and an LSAM Additive Trimmer, you can print and trim at the same time.

Although having a new LSAM Additive Printer plus an LSAM Additive Trimmer requires purchasing two machines, the combined cost of both is just over a third of the cost of an LSAM 1020 (which is currently the smallest flagship LSAM system that can both print and trim at the same time). The LSAM 1020 does have a much larger table, faster print head and the ability to do vertical layer printing up to 20 feet long, however, if you don’t need those capabilities, the new LSAM Additive Printers may be an answer. If you already have trim capability, the cost can be even lower.

Same Powerful Features

The same powerful, feature rich LSAM control used on the large flagship LSAM systems, along with all its unique patented additive print features is standard on the new LSAM Additive Printers. A system for drying and conveying pelletized polymer material is also included as is a liquid chilling system to maintain temperature control on vital systems. This is especially important when processing high temperature materials.

Optional Enclosure

An optional enclosure that surrounds the machine is available.   The machine with this full enclosure can also be built to meet European CE standards.

Optional Dual Hopper Dryer

The machine comes standard with a single hopper material dryer, however, an optional dual hopper dryer is also available for applications that change materials often.

Thermal Sensor Layer Automation System

Thermwood’s new Thermal Sensor Layer Automation System is also available on the LSAM Additive Printers. This is an exciting new system that automates the print process to easily and automatically obtain the highest quality layer to layer fusion.

With this system, a servo controlled thermal sensor, which travels with and rotates around the print nozzle, measures the temperature of the bead an instant before a new bead is added. This data is sent to the control which automatically adjusts print speed to print at the precise temperature that results in the best bead fusion for that particular polymer. Thermwood’s

LSAM print technology already produces the best quality, strongest large scale additive parts and this system not only makes it better but also easier.

Same Powerful Print 3D Slicing Software

The same Thermwood LSAM Print 3D slicing software used on all the other LSAM systems is used to program LSAM Additive Printers. Several levels of software training are available.

The Bottom Line

This new LSAM Additive Printer is intended to introduce LSAM additive technology to a whole new level of application and customer. It targets companies that want to print top quality, large composite thermoplastic parts, but don’t really need, nor can they cost-justify, the really large LSAM systems. These new systems also target companies who already have sufficient trimming capability and may only need a quality print function. Applications include industrial fixtures, molds (including high temperature molds), tooling, foundry patterns, and hundreds, if not thousands of similar applications.

With the addition of the LSAM Additive Printers, Thermwood now offers the largest selection of large scale additive manufacturing systems for thermoplastic composite materials in the industry with models available for just about every application and budget.