Thermwood has completed the first of a new type of additive print and trim system, the LSAM 1010. This is a fixed table, high wall system with both print and trim head mounted on a single gantry. Although with a ten foot by ten foot table, it is a bit smaller than the larger dual gantry flagship LSAM systems, it does require a significantly larger gantry.

The LSAM 1010 can both print and trim, but not at the same time. It uses the same 40mm print head that is standard on the larger LSAM systems and the same five axis trim head. It has the same 5 foot high print and trim capability of the larger machines. The addition of both of these on a single gantry adds two major new requirements.

Two Major New Requirements

First, the gantry must be significantly longer to accommodate the width of both heads, while also allowing both heads to cover the entire table.

Also, the gantry must be significantly stronger to rigidly support both the print and trim head, which together weigh well over 7,000 pounds, resulting in a live load (the parts of the machine that actually move) of over 18,000 pounds. Despite the weight, the machine can move at speeds up to almost three feet per second.  This is not a small machine.

New M400 Helps Build Large Machines

The production of this new gantry has been made possible by the commissioning of Thermwood’s new M400 five axis metal working system which can machine parts up to 35 feet long. The gantry design uses Thermwood’s slot and tab construction method which produces engineered steel structures that are extremely strong and stiff. 

More Details About the LSAM 1010

Since the LSAM 1010 has a fixed table, there is no practical part weight limitation. 

The LSAM 1010 has the same 200 lb maximum print rate capability of the larger flagship LSAM systems but is still priced well under the LSAM 1020, which is the smallest dual gantry LSAM available. 

The LSAM 1010 is also available as a “print only” machine for companies who already have the necessary machining capacity, bringing the price down even more. 

The LSAM 1010 is ideal for companies whose size requirements fit the available envelope and where a sequential process production rate (print and then trim) is adequate. It is also ideal for companies who need relatively large, heavy parts but don’t need trim capability. The lower price point also makes the LSAM 1010 easier to cost justify for a wider variety of end applications. 

Largest Selection of Large Scale Additive Manufacturing Systems

The LSAM 1010 is part of the LSAM product line which offers the largest selection of large scale additive manufacturing systems available anywhere. There is a system available for about any large scale additive requirement from a 5x5 Additive (Print Only) Printer to giant, dual gantry, print and trim machines up to 40 foot long. Longer machines are available however, 40 foot are the longest machines produced to date. 

Large Scale Additive Manufacturing Systems from the industry leader, LSAM by Thermwood.

Learn More About Large Scale Additive Manufacturing Systems from the industry leader, LSAM by Thermwood.

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.

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.

Six new Thermwood Model 42 3 Axis CNC Routers shipping out to the same customer. These six  will make the number over 30 Model 42s that this customer has purchased!

 

 

Video tour of the Model 42

Learn about the different aspects of the 3 Axis Model 42 and watch as it machines small tables in a machine-paced operation.

The Model 42 is a moving table, fixed gantry, CNC router primarily designed to machine low profile materials such as hardwoods, softwoods, fiberboard (MDF), particleboard, plastics and aluminum.

Thermwood LSAM 2020 - Year in Review

The last 12 months have seen an incredible level of disruption in all industries, fueled in large part by the coronavirus pandemic.  COVID-19 has impacted nearly every aspect of the global economy, from manufacturing to supply chains to travel.

The additive industry wasn’t spared, with event cancellations and disruptions to regular business becoming the norm.  Thermwood pivoted in 2020 to continue our focus on innovation and development with our LSAM (Large Scale Additive Systems) line, and have made many new discoveries and advancements in our additive manufacturing program.

Below, we highlight some of the notable LSAM moments from 2020 that leaves us hopeful for the future of large scale additive manufacturing in 2021 and beyond:

March 5th - Thermwood Announces Another New LSAM Model

To address the need for a lower cost enclosed additive machine, Thermwood developed the LSAM 1010. This system uses the walls from the larger LSAM systems with the gantry, control and sub-systems from the LSAM MT. 

The LSAM 1010 features a fixed 10 foot by 10 foot table. A single moving gantry carries both the print and trim heads as on the MT and, like the MT, it can both print and trim (but not at the same time). The print and trim heads on all Thermwood LSAMs are the same, so all machines can process virtually any reinforced composite thermoplastic materials available today.

With the introduction of the LSAM 1010, it became clear that Thermwood is committed to responding to customer requests and providing its industry-leading LSAM additive manufacturing technology in a variety of configurations to better fit varying customer requirements.

March 17th - Thermwood LSAM 1020 Quickly 3D Prints a Multi-Piece Foundry Pattern

This was a great exercise to demonstrate the capabilities of an LSAM to quickly make a multi-piece foundry pattern out of ABS (20% carbon fiber fill). 

The pattern was printed on an LSAM 1020 in 6 hours and 40 minutes, and machined on a Thermwood 5 Axis Model 90 (because of other projects that were pending on the LSAM).

More info

June 25th - Thermwood Builds Massive Metalworking Machine to Increase LSAM Production

Thermwood designed, fabricated and put into operation the largest machine it has ever built. The metalworking machine, dubbed internally as the M400, weighs 51 Tons (103,000 pounds) and is mounted on a special isolated, double steel reinforced concrete pad. It has a 15 foot wide, 35 foot long floor level steel table that by itself weighs 21,000 pounds.

More info

August 27th - Thermwood LSAM MT VLP Prints a High Temperature Part

In August, Thermwood demonstrated it's VLP (Vertical Layer Printing) capabilities on an LSAM MT 1010.  The high-temperature part was printed out of Techmer PM blended 25% carbon fiber filled PSU/PESU. 

Total print time for the project was 16 hours and 40 minutes, and the final weight of the part was 1,190 lbs.  The final part dimensions were 108.6" (x) x 33" (Y) x 45" (Z).

More info

September 17th - Thermwood and General Atomics Partner on Additive Tool with $50,000 Cost Savings

In September, Thermwood partnered with General Atomics to produce a CNC trim tool.  The tool was printed from ABS (20% Carbon Fiber Filled) in 16 hours.  Total machining time was 32 hours.  The final part weighed 1,190 lbs, and represented a cost savings of around $50,000 when compared to traditional methods.

Total lead time for the part decreased from 6-8 weeks to less than 2 weeks by utilizing the powerful LSAM system.

More info

September 24th - Take a Tour of the Thermwood LSAM

Also in September, LSAM Product Manager, Scott Vaal, took us on an informative tour of the Thermwood LSAM.

In this tour, Scott explains all the different aspects of the Thermwood LSAM and provides insight into this unique solution for large scale additive manufacturing.  

More info

October 22nd - A New Approach to 3D Printing a Yacht Hull Mold

In October, Thermwood printed a several sections from a 51 foot long yacht hull mold to demonstrate how only a single mold may be needed for the manufacture of larger vessels, such as yachts. 

The printed sections of this test mold were made of carbon fiber reinforced ABS from Techmer PM. ABS was chosen because of its physical properties and relatively low cost compared to other reinforced thermoplastics

More info

With this latest update, we have expanded the capabilities of the Publisher beyond just sending your own custom cabinet designs to Cut Ready.  Now you have the ability to send Kitchen Layouts and Batch Lists too.

Finished Ends for Combination Cabinets

This part of the update completes the finished end options for frameless cabinets, which now adds a 2^nd option for exposed ends.  Instead of applying a door or panel, choose to make it a finished end!

Moldings Updates

As requested by our users, we’ve added the ability to save molding jobs much like you do with cabinets, drawers, doors, etc.

Shapes Updates

Also, as requested by users, we've added the ability to specify grain direction for your shapes.

Cut Ready Interface

Enhancements and improvements to the user interface give it a more polished feel overall.

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

Tour the Cut Ready Cut Center

Design a Cabinet and Add it to the Job

Cut Out a Cabinet Job

Watch a Thermwood Model 45 5'x10' Machine an Aluminum Sign

The Model 45 is a heavy-duty and versatile three axis CNC designed for composites, plastics, aluminum, cabinets, wood and nested base panels.  Available in either single or dual spindles with optional rotary axis. Available Table Sizes:  5'x'5, 5'x10', 5'x12', 6'x12' and 7'x12'

Model 45 5'x10' CNC Router - Learn More

• Time extension (ADDED)
• Constraints are being removed from drawer box (FIXED)
• Full Dado for left side to deck construction does not allow constraints to be modified (FIXED)
• Missing cabinets after adjusting material thickness (FIXED)
• Corner cabinet door resizing wrong (FIXED)
• When focus is on Item Window, the explode slider still moves (FIXED)
• When editing name of a cabinet, the name does not automatically highlight when the dialog opens (FIXED)
• When a slab door/drawer with banding is added from the Item Window, the nest label is missing banding info (FIXED)
• When KD/RTA pattern is used for a partition to the top stretcher, the holes do not create correctly (FIXED)
• Using Global Item Modification to change to a single sided material does not allow you to immediately change what is A side (FIXED)
• Making a change to one cabinet applies the change to another cabinet in the layout (FIXED)
• Formula for missing part is not staying after it is set (FIXED)
• Depth constraint causes error message (FIXED)
• Apply toe kick notch to none does not accept none after uncheck has toe (FIXED)
• When a cabinet with specific settings, the top disappears and tenon is created in space (FIXED)
• Cannot remove deck float value when bottom rail doesn't exist (FIXED)
• Using upper corner cabinet, pocket screw inset values are reversed front and back (FIXED)
• When cursor is in width, height, or depth, cabinet explode does not work correctly (FIXED)

Watch a Thermwood Model 45 5'x10' Machine a Bar Stool Leg using an Optional Rotary Playback Device and aggregate tooling.

The Model 45 is a heavy-duty and versatile three axis CNC designed for composites, plastics, aluminum, cabinets, wood and nested base panels.  Available in either single or dual spindles with optional rotary axis. Available Table Sizes:  5'x'5, 5'x10', 5'x12', 6'x12' and 7'x12'

Model 45 5'x10' CNC Router - Learn More

IWF Connect is going on now! From Oct 26-30th, you can explore our product offerings, watch videos on different applications and see our live demonstrations each day.

 

Cut Ready Product Manager, Jody Wilmes, walks you through the simple steps of running a cabinet job on the Thermwood Cut Center. 

He also provides real-world examples of how the software helps guide you, even if you run into a problem...like breaking a tool.

Check out some of our previous Cut Center Demo Videos:

CNC Router vs. Cut Center

Tour the Cut Ready Cut Center

How to Design a Cabinet and Add it to the Job