Layer Time Control optimizes speed and temperature for perfect fusion

In today's installment on the groundbreaking capabilities of Thermwood's Large Scale Additive Manufacturing (LSAM) systems, we’re spotlighting a feature that brings next level of precision and efficiency with Thermwood’s Layer Time Control technology, built directly into the LSAM control system.

 

This cutting-edge feature automatically adjusts print speed in real-time, ensuring each layer remains at an optimal temperature for flawless layer fusion. By dynamically managing heat and timing throughout the print process, our technology guarantees exceptional results while offering real-time adjustments—even as the machine is printing. Unlock the full potential of your additive manufacturing with superior Layer Time Control technology, where precision meets performance.

 

𝐒𝐮𝐩𝐞𝐫𝐢𝐨𝐫 𝐋𝐚𝐲𝐞𝐫 𝐂𝐨𝐧𝐭𝐫𝐨𝐥:
• Technology built into the LSAM control system
• Automatically controls the time spent on each layer by adjusting the print speed
• Dynamically handled at the control in real time
• Ensures that the print is staying at an optimal print temperature at all times
• Can be immediately adjusted (while the machine is printing)
• Optimal temperature range results in better layer fusion

 

 

Some Powerful Advantages:

• Wide variety of "Print-Ready" materials available - including high-temp

• One click activation to apply all parameters necessary to print

• Material configuration files can be shared with all LSAMs

• Automatic routines to load, empty, purge and clean materials from the system

• On-screen instructions guide the operator

• Total freedom to source material from any supplier

• Thermwood will assist in qualifying new materials and train you to qualify new materials yourself.

• Freedom to work directly with material suppliers to develop specialty materials for your specific application.

Thermwood has been the market and technology leader in Large Format Additive Manufacturing (LFAM) since 2016, thanks to our groundbreaking LSAM (Large Scale Additive Manufacturing) systems. 

 

𝐋𝐒𝐀𝐌 𝐒𝐲𝐬𝐭𝐞𝐦𝐬 𝐎𝐟𝐟𝐞𝐫:

- Superior Print Consistency

- Dynamic Control of Print Temperature

- Large Scale Focused Slicing Software

- Confidence Through Thermwood's Legendary Training, Service and Support

Stay tuned for more insights into how our LSAM systems are revolutionizing large format additive manufacturing! 

Configure and qualify materials effortlessly for large-scale additive manufacturing.

In our latest installment on the groundbreaking capabilities of Thermwood's Large Scale Additive Manufacturing (LSAM) systems, we’re spotlighting a feature that brings unmatched material flexibility and simplicity to large-scale 3D printing: Thermwood’s streamlined approach to material configuration.

 

Discover new levels of material flexibility and ease of use with Thermwood's LSAM (Large Scale Additive Manufacturing) systems! With LSAM, you can access a wide range of “print-ready” materials, all with one-click activation to streamline setup.

 

Our systems come equipped with material configuration files that can be shared across all LSAM units, along with automatic routines for loading, purging, and cleaning, ensuring smooth transitions and hassle-free operation.  Plus, Thermwood gives you total freedom to work with any material supplier, develop specialty materials for unique applications, and we’ll assist you in qualifying new materials while training you to do the same independently. 

 

Some Powerful Advantages:

• Wide variety of "Print-Ready" materials available - including high-temp

• One click activation to apply all parameters necessary to print

• Material configuration files can be shared with all LSAMs

• Automatic routines to load, empty, purge and clean materials from the system

• On-screen instructions guide the operator

• Total freedom to source material from any supplier

• Thermwood will assist in qualifying new materials and train you to qualify new materials yourself.

• Freedom to work directly with material suppliers to develop specialty materials for your specific application.

Thermwood has been the market and technology leader in Large Format Additive Manufacturing (LFAM) since 2016, thanks to our groundbreaking LSAM (Large Scale Additive Manufacturing) systems. 

 

𝐋𝐒𝐀𝐌 𝐒𝐲𝐬𝐭𝐞𝐦𝐬 𝐎𝐟𝐟𝐞𝐫:

- Superior Print Consistency

- Dynamic Control of Print Temperature

- Large Scale Focused Slicing Software

- Confidence Through Thermwood's Legendary Training, Service and Support

Stay tuned for more insights into how our LSAM systems are revolutionizing large format additive manufacturing! 

Explore Thermwood's Patented Bead Board Substrate

In our latest installment on the transformative power of Thermwood’s Large Scale Additive Manufacturing (LSAM) systems, we're showcasing an clever innovation that’s reshaping additive manufacturing: the Patented Bead Board Substrate.

 

This unique substrate offers unparalleled strength and flexibility, providing a stable foundation for your printed parts while preventing stress and distortion—a common issue in traditional substrates. With advantages like a strong initial tack, secure holding during printing, and effortless removal with basic tools, our bead board substrate sets a new standard in reliability and reusability. Join us as we explore how LSAM technology from Thermwood continues to lead the way in advanced manufacturing solutions!

 

Some Powerful Advantages:

• Strong initial tack

• Allows the printed part to float during its initial contact

• Holds strong throughout the entire printing process

• Prevents distortion/stresses that build in other substrates

• Holds well enough for initial machining operations

• Removed easily with simple everyday tools

• Reusable and repairable

Thermwood has been the market and technology leader in Large Format Additive Manufacturing (LFAM) since 2016, thanks to our groundbreaking LSAM (Large Scale Additive Manufacturing) systems. 

 

𝐋𝐒𝐀𝐌 𝐒𝐲𝐬𝐭𝐞𝐦𝐬 𝐎𝐟𝐟𝐞𝐫:

- Superior Print Consistency

- Dynamic Control of Print Temperature

- Large Scale Focused Slicing Software

- Confidence Through Thermwood's Legendary Training, Service and Support

Stay tuned for more insights into how our LSAM systems are revolutionizing large format additive manufacturing! 

 

Explore Thermwood's Patented LSAM Chilled Compression Wheel

Discover the latest in our LSAM series! Today, we’re highlighting Thermwood’s Patented Chilled Compression Wheel — engineered for precision, bead consistency, and enhanced bonding strength, delivering fused structures that surpass aerospace standards. See how Thermwood’s LSAM continues to lead in Large Format Additive Manufacturing! 

 

𝐒𝐨𝐦𝐞 𝐩𝐨𝐰𝐞𝐫𝐟𝐮𝐥 𝐚𝐝𝐯𝐚𝐧𝐭𝐚𝐠𝐞𝐬:

• Finishes the bead's final shape and dimension

• Provides important active bead compaction

• The nozzle tip is slightly above the finished bead height

• Nozzle tip does not drag through the material to form the final shape

• Prevents excessive material build up on the nozzle

• Temperature controlled only to prevent polymer affinity (sticking to wheel)

• Removal of inter-bead voids

• Consistency in printed composite microstructures

• Enhances interlayer bonding

• Enhances lateral bead to bead solidity

• Layer-to-layer fusion is over 50% GREATER in strength when compared to methods that utilize a tamping device or those that have no application device at all.

• This results in fused, solid structures that hold vacuum exceeding aerospace standards, 𝐰𝐢𝐭𝐡𝐨𝐮𝐭 the need for fill compounds or sealants.

Thermwood has been the market and technology leader in Large Format Additive Manufacturing (LFAM) since 2016, thanks to our groundbreaking LSAM (Large Scale Additive Manufacturing) systems. 

 

𝐋𝐒𝐀𝐌 𝐒𝐲𝐬𝐭𝐞𝐦𝐬 𝐎𝐟𝐟𝐞𝐫:

- Superior Print Consistency

- Dynamic Control of Print Temperature

- Large Scale Focused Slicing Software

- Confidence Through Thermwood's Legendary Training, Service and Support

Stay tuned for more insights into how our LSAM systems are revolutionizing large format additive manufacturing!

 

 

Explore the Game-Changing Melt Core System in Thermwood’s LSAM Technology

Thermwood has been pioneering Large Format Additive Manufacturing (LFAM) since 2016, leading the industry with our advanced LSAM systems. These machines offer more than just large-scale capabilities—they deliver an unmatched printing experience with superior print consistency, precise temperature control, and powerful slicing software.

In this series, we’ll take you through the exclusive benefits of LSAM technology, starting with our patented Melt Core System. Discover how this cutting-edge innovation redefines material processing to achieve faster, more reliable, and efficient large-scale 3D printing. Ready to explore the future of manufacturing? Dive in and see why Thermwood is the leader in LFAM! 

 

 

• High output deposition rates
• Large consistent bead sizes
• Standard Melt Core producing over 200 lbs/hr (90.72 kg/hr)
• Optional Larger Melt Core producing over 500 lbs/hr (226.8 kg/hr)
• PID heater control to tightly maintain processing temperatures
• Up to 450° C (850° F) processing temperatures
• Custom Industrial Extruder Screw
• Compression Following Wheel (temperature-controlled) 

---

Thermwood Patented Polymer Melt Pump

• Custom patented extruder screw design
• Provides a more consistent melt temperature
• Material flows from the extruder into a fixed displacement polymer melt pump system (patented)
• Melt Pump precisely delivers material to the nozzle
• Eliminates the problem of Extruder Surging
• Not necessary to change the extruder screw when switching between different materials

Thermwood LSAM 1020 Printing and Machining a High Temperature Aerospace Tool for ST Engineering (MRAS) 

𝐖𝐡𝐲 𝐓𝐡𝐞𝐫𝐦𝐰𝐨𝐨𝐝 𝐋𝐒𝐀𝐌?

• Precision for demanding aerospace applications

• Fastest print heads in the industry – print at speeds up to 200 lbs to 500 lbs per hour

• Built to handle high-temperature materials

• Fast and precise machining capabilities

• Print and Trim at the same time on the same machine for maximum efficiency

• Process virtually any thermoplastic composite, including high-temp materials

𝐋𝐞𝐚𝐫𝐧 𝐦𝐨𝐫𝐞 𝐚𝐛𝐨𝐮𝐭 𝐋𝐒𝐀𝐌: https://bit.ly/3BQqfV9

Ever wondered how you can produce large format, near-net-shape parts faster and more affordably? Check out this innovative use of Thermwood’s Cut Layer Additive process in action!

Watch as CLA creates a Trim and Drill Vacuum Fixture using RAKU Tool SB-0497 with remarkable precision and speed. This method slashes production costs while maintaining top-quality results.  See how cutting layers, rather than printing them, is making large-scale manufacturing easier and more efficient than ever

Project Details:

• Trim and Drill Vacuum Fixture made from RAKU Tool SB-0497
• CLA Software Processing Time: 13 minutes 48 seconds
• CLA Machining Near Net Shape Layers Time: 1 hour 4 minutes
• Assembly Time: 2 hours with 2 employees
• Total 5 axis Trimming Time: 35 hours

Cut Layer Additive is a powerful new additive approach that produces large format, near-net-shape parts at incredibly low cost, using a lower cost additive machine. Unlike large format additive printers (like Thermwood’s LSAM), the new process makes large parts from a variety of materials that can’t be printed.

Cut Layer Additive parts are similar to large additively printed parts, in that they are essentially hollow structures made in layers. However, instead of printing the layers, they are instead cut from thick sheets.

LSAM 5 Axis Trimming Capabilities

🔍 Did you know our cutting-edge LSAM systems can be configured with a separate 5-axis trimming head?

🚀 Like this LSAM 1020 flagship model, for example. It features a dual-gantry setup where one gantry can print while the other trims simultaneously, streamlining your workflow like never before!

 Here’s a quick rundown of our innovative models:

• 𝐋𝐒𝐀𝐌 𝟏𝟎𝟏𝟎: A closed high-wall system with doors on each end, featuring a single control with both print and trim heads on one moving gantry. Efficient and compact!
  
  
•  𝐋𝐒𝐀𝐌 𝟏𝟎𝟐𝟎/𝟏𝟎𝟒𝟎/𝟏𝟓𝟒𝟎: These models also feature a closed high-wall
  configuration with doors on each end, equipped with dual controls and dual gantries for separate print and trim operations. Perfect for maximizing productivity! 
  
  
•  𝐋𝐒𝐀𝐌 𝐌𝐓: Designed with an open configuration, it has a single fixed gantry over a moving table, integrating print and trim functions seamlessly. 
  
  
•  𝐋𝐒𝐀𝐌 𝐀𝐏 𝟓𝟓/𝟓𝟏𝟎: These systems offer an open configuration, with optional enclosures available. They focus on printing only, with a fixed gantry over a moving table, ideal for specialized tasks.  

We offer the broadest range of LFAM systems in the industry, to help you find the perfect solution for your needs and budget. But LSAM systems are more than just 3D printers - they're real production systems, capable of producing industrial fixtures, molds (including high temp), tooling, foundry patterns, prototypes and end products from a wide variety of both low and high temp materials.

𝗔 𝗳𝗲𝘄 𝗟𝗦𝗔𝗠 𝗮𝗱𝘃𝗮𝗻𝘁𝗮𝗴𝗲𝘀:

• LSAM systems offer three printing orientations - HLP (Horizontal Layer Printing), VLP (Vertical Layer Printing), allowing parts to be printed that are as long as the machine table and ALP (Angle Layer Printing), the ability to print at a 45 degree angle.

• With the fastest print heads in the industry, our LSAM systems can print at speeds from up to 200lbs per hours to over 500 lbs per hour.

• Choose from Print-only or Print-and-Trim combinations with table sizes ranging from 5’x5’ to 15’x40’ and beyond.

• Save both time and money over traditional methods - case study here: https://bit.ly/3zWoWjk

 

𝗦𝗲𝗲 𝘂𝘀 𝗹𝗶𝘃𝗲:

We will next be printing LIVE at IMTS 2024 in Chicago, IL (booth #433103) starting on September 9th with an LSAM AP 510 - visit us to learn more about LSAM, or you can always contact us directly to arrange a personal demonstration at our corporate headquarters.

 

Learn More About LSAM:

LSAM 1540 Shown

Molds, for plastics processes, such as thermoforming, blow molding, rotational molding and reaction injection molding are commonly made of aluminum. Often, they are large.

Thermwood has developed a simplified, low cost way of making these large molds, using its new Cut Layer Additive process.

How Does This Work?

Cut Layer Additive works by laminating layers, cut from thick sheets of material, such as aluminum, to create a structure. In addition to building highly efficient structures, the process offers unique capabilities that make it ideal for large plastic molds.

The most important element of a mold is the mold face, essentially the cavity that defines the size and shape of the part. It’s the one thing you absolutely have to have.

Depending on the process, other functions may also be needed, such as vacuum, venting and/or temperature control. Adding these functions usually increases complexity and cost, sometimes significantly.

Thermwood’s new approach incorporates these functions in a mold face that is only a couple inches thick. So, the entire mold, including all required functions, is just the mold face.

It’s simple and less expensive. Cut Layer Additive makes it possible.  In this process, the mold face is built using machined aluminum layers, stacked and permanently attached. Since, prior to assembly, each layer is machined individually in a nest, it is possible to include holes or slots so that, when assembled, they match up, creating internal channels or chambers. These void areas in the mold are then accessed by boring holes from underneath into the opening. 

Design Flexibility is Incredible

A channel with an access hole on each end can be used to circulate temperature-controlled liquid, to control mold temperature.

An internal chamber can be also be used for vacuum. Small holes are drilled into the chamber, as is normally done with thermoforming molds. Vacuum applied to the chamber then forms the part.

Thin slots can be machined between layers to provide vents, should they be needed for certain processes.

Design flexibility is incredible.

In this way, all required functions can be included in a relatively thin mold face.

For mounting, selected mold layers are extended downward to create standoffs supports.

This means large molds can now be produced at surprisingly low cost.  This new approach also supports some advanced features.

Inner views of layers of the mold with holes and slots in place

Because you can create a multitude of channels or chambers inside the mold face, you can easily do things that are not normally possible. For example, you can circulate liquid at different temperatures through different parts of the mold, or you can create vacuum chambers under different areas of the mold and regulate the flow and timing of vacuum to those areas to aid in forming difficult parts.

There are few, if any, restrictions as to the size or geometry of molds that can be produced using this approach.

Although the basic idea is quite simple, there are a lot of details that must come together to make it all work. Programing all these details using traditional CAD would be difficult at best. The effort would likely make the whole approach impractical.

With Cut Layer Additive, the basic mold doesn’t require programming, at least in the usual sense.

Machine Intelligence in the Cut Layer Additive machine actually knows how to make these kinds of molds, so all you need to do is tell it what you want.

This is done in two steps, show it the shape and tell it how you want it made.

The basic shape of the part is all CLA needs

CLA just needs a CAD file of the basic shape

You show it the shape by sending it a CAD file. Not a detail file, just the basic shape you want. Don’t worry about the inside just yet.

In telling it how you want it made, you need to tell it the material you want to use, how thick you want the face, where you want channels, where you want standoffs, and any other details of what you want.

This is actually a lot easier than it sounds. You simply answer questions about how you want it made. The system guides you and makes the entire process rather easy. This part can often be done in less than five minutes.

CLA can add in holes and slots to each layer to create channels and chambers

To make molds, Thermwood has added the ability to add holes and slots to each layer to create channels and chambers. New features, while you are defining the part, make this rather easy to do. It does take a bit more effort than just making a cut layer part, but overall, it’s straightforward and the results are stunning.

Truly sophisticated molds are now possible at low cost, with zone temperature control, zone vacuum and more. Cut Layer Additive does it using a tiny fraction of the time it would otherwise take.

It makes the whole thing practical.

CLA can quickly create the mold with holes and slots that couldn't be made any other way. 

Attend CAMX 2023 FREE and see CLA for yourself

CLA will be on display at CAMX 2023 Oct 31st-Nov 2nd in Atlanta, GA!  Visit Thermwood Booth #FF18 to see molds and tools produced on CLA, experience live demonstrations of the software and speak to our representatives to help answer your questions on this exciting new addition to the world of additive manufacturing!

Use the code 119734 to register and attend CAMX 2023 Free from Thermwood at the link below:
https://www.xpressreg.net/register/camx1123/start.asp

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