Unlock Unmatched Internal Strength with LSAM Print3D’s Brace Feature

Posted by Duane Marrett on Thu, Jun 05, 2025

Tags: Additive, LSAM, Additive Manufacturing, LFAM, LSAM Print 3D, Brace Feature


Transform Large-Scale Prints with Custom Internal Bracing

In large-scale additive manufacturing, traditional infill strategies often fall short—especially for complex, high-performance applications like autoclave tooling and CNC fixtures.

That’s why LSAM Print3D’s patent-pending Brace feature gives users the ability to design and place custom internal bracing directly within the part.

✔️ Precisely positioned internal support—exactly where it’s needed
✔️ Surface- or solid-based geometry with near-limitless complexity
✔️ Automatic connections along curved and compound boundaries
✔️ Stronger parts, smarter material use—no overbuilding required

From simple headers to intricate support structures, the Brace feature enhances strength and performance without compromising your design.

Just one of the many powerful capabilities that sets LSAM Print3D apart.

Engineered for flexibility. Built for performance. Powered by Thermwood. 
 
 thm_lsam_logo_600_232-1

Learn More About LSAM

 
Learn more about Thermwood’s LSAM systems: https://bit.ly/4kP4l66

LSAM Info Request

 

LSAM 1540

LSAM 1540 Shown

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Thermwood LSAM 1540 Additive System in Production

Posted by Duane Marrett on Wed, Jun 04, 2025

Tags: Additive, LSAM, Additive Manufacturing, VLP, High Temperature, ALP, HLP, LFAM, LSAM1540

Thermwood LSAM

DJI_0275-2

2-Jun-04-2025-01-43-36-7787-PM-1

3-Jun-04-2025-01-44-09-5915-PM-1

Another LSAM 1540 is in the works — what could YOU build with this additive titan?
Thermwood is building another powerhouse in our LSAM (Large Scale Additive Manufacturing) line — a high-performance 1540 model designed to produce massive, high-precision components. 
This system is packed with advanced capabilities:
 
Print Gantry:
✅ Patented 60mm melt core
✅ Prints up to 500 lbs per hour
✅ Handles both low- and high-temp thermoplastics
✅ Operates at temperatures up to 450°C
✅ 60" vertical stroke for tall part production
✅ Self-contained fume and smoke collection system
 
5-Axis Trim Gantry:
✅ 72" vertical stroke
✅ 362° horizontal and 270° vertical rotation
✅ Multi-axis feed speeds up to 2,100 inches per minute
✅ High-performance 24HP, 24,000 RPM variable-speed router
✅ 12-position automatic tool changer located under the gantry
✅ Automatic lubrication system for reduced maintenance
✅ High-tolerance automatic tool length sensor
✅ Superior chip collection system
✅ Can print and trim at the same time — no part relocation needed
 
Three Print Orientations:
🔹 Vertical Layer Printing (VLP): Print full-length parts in a single section
🔹 Standard Horizontal Printing
🔹 Angle Layer Printing (ALP): Print at a 45° angle for complex geometry
 
This LSAM 1540 is built for speed, scale, and flexibility — and it's almost ready. Stay tuned for updates as it nears completion!
 

Learn More About LSAM

 
Learn more about Thermwood’s LSAM systems: https://bit.ly/4kP4l66

LSAM Info Request

 

LSAM 1540

LSAM 1540 Shown

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Another Powerful Thermwood LSAM Tool - Layer Time Control

Posted by Duane Marrett on Mon, Nov 04, 2024

Tags: Additive, LSAM, Additive Manufacturing, Patented, LSAM 1020, High Temperature, LFAM, Features, High Temperature Material, Layer Time Control

 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
 Real-time technology built into the LSAM system that optimizes print speed and temperature for perfect layer fusion, ensuring precise, high-quality results every time.
 
Real-time technology built into the LSAM system that optimizes print speed and temperature for perfect layer fusion, ensuring precise, high-quality results every time.

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! 

𝗦𝗲𝗲 𝘂𝘀 𝗹𝗶𝘃𝗲 at JEC 2025!
See LSAM printing LIVE at JEC World 2025
We will next be printing with material from a variety of suppliers on an LSAM AP 510 LIVE at JEC World 2025 in Paris, France (Hall 6 - Live Demo Area) on March 4th-6th.  Visit our booth to learn more about LSAM, and you can always contact us directly to arrange a personal demonstration at our corporate headquarters.
 
Don't settle for less when it comes to your production process. Upgrade to Thermwood's LSAM system and take your manufacturing to the next level! Learn more about LSAM.

LSAM Info Request
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Another Advantage of Thermwood LSAM - Material Flexibility and Ease of Use

Posted by Duane Marrett on Fri, Nov 01, 2024

Tags: Additive, LSAM, Additive Manufacturing, Patented, LSAM 1020, High Temperature, LFAM, Features, High Temperature Material, Material Flexibility

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. 
 Another Advantage of Thermwood LSAM - Material Flexibility and Ease of Use

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! 

𝗦𝗲𝗲 𝘂𝘀 𝗹𝗶𝘃𝗲 at JEC 2025!
See LSAM printing LIVE at JEC World 2025
We will next be printing with material from a variety of suppliers on an LSAM AP 510 LIVE at JEC World 2025 in Paris, France (Hall 6 - Live Demo Area) on March 4th-6th.  Visit our booth to learn more about LSAM, and you can always contact us directly to arrange a personal demonstration at our corporate headquarters.
 
Don't settle for less when it comes to your production process. Upgrade to Thermwood's LSAM system and take your manufacturing to the next level! Learn more about LSAM.

LSAM Info Request
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Discover the Power of Thermwood’s Patented Bead Board Substrate for Superior Additive Manufacturing

Posted by Duane Marrett on Thu, Oct 31, 2024

Tags: substrates, Additive, LSAM, Additive Manufacturing, Patented, LSAM 1020, High Temperature, LFAM, Features, Bead Board

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!
 Discover the Power of Thermwood’s Patented Bead Board Substrate for Superior Additive Manufacturing

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! 
 
Discover the Power of Thermwood’s Patented Bead Board Substrate for Superior Additive Manufacturing

 

𝗦𝗲𝗲 𝘂𝘀 𝗹𝗶𝘃𝗲 at JEC 2025!
See LSAM printing LIVE at JEC World 2025
We will next be printing with material from a variety of suppliers on an LSAM AP 510 LIVE at JEC World 2025 in Paris, France (Hall 6 - Live Demo Area) on March 4th-6th.  Visit our booth to learn more about LSAM, and you can always contact us directly to arrange a personal demonstration at our corporate headquarters.
 
Don't settle for less when it comes to your production process. Upgrade to Thermwood's LSAM system and take your manufacturing to the next level! Learn more about LSAM.

LSAM Info Request
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Explore Thermwood's Patented LSAM Chilled Compression Wheel

Posted by Duane Marrett on Wed, Oct 30, 2024

Tags: Additive, LSAM, Additive Manufacturing, Patented, LSAM 1020, High Temperature, Compression Wheel, LFAM, Features

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 Thermwood's Patented LSAM Chilled Compression Wheel
 
Explore Thermwood's Patented LSAM Chilled Compression Wheel

 

𝗦𝗲𝗲 𝘂𝘀 𝗹𝗶𝘃𝗲 at JEC 2025!
See LSAM printing LIVE at JEC World 2025
We will next be printing with material from a variety of suppliers on an LSAM AP 510 LIVE at JEC World 2025 in Paris, France (Hall 6 - Live Demo Area) on March 4th-6th.  Visit our booth to learn more about LSAM, and you can always contact us directly to arrange a personal demonstration at our corporate headquarters.
 
Don't settle for less when it comes to your production process. Upgrade to Thermwood's LSAM system and take your manufacturing to the next level! Learn more about LSAM.

LSAM Info Request
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Revolution in Additive Manufacturing: Inside Thermwood LSAM’s Patented Melt Core System

Posted by Duane Marrett on Tue, Oct 29, 2024

Tags: Additive, LSAM, Additive Manufacturing, Patented, Melt Core, LSAM 1020, High Temperature, LFAM, Features

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! 

 Thermwood Patented Melt Core System
 
  • 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

LSAM 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

𝗦𝗲𝗲 𝘂𝘀 𝗹𝗶𝘃𝗲 at JEC 2025!
jec_2025_live_printing_image
We will next be printing with material from a variety of suppliers on an LSAM AP 510 LIVE at JEC World 2025 in Paris, France (Hall 6 - Live Demo Area) on March 4th-6th.  Visit our booth to learn more about LSAM, and you can always contact us directly to arrange a personal demonstration at our corporate headquarters.
 
Don't settle for less when it comes to your production process. Upgrade to Thermwood's LSAM system and take your manufacturing to the next level! Learn more about LSAM.

LSAM Info Request
0 Comments Click here to read/write comments

Thermwood LSAM 1020 Printing and Machining a High Temperature Aerospace Tool

Posted by Duane Marrett on Fri, Oct 25, 2024

Tags: Demonstrations, Additive, LSAM, Additive Manufacturing, LSAM 1020, High Temperature, LFAM, ST Engineering

From Print to Precision: LSAM 1020 Crafts a High-Temp Aerospace Tool for ST Engineering MRAS

 
 
See how quickly the versatile Thermwood LSAM 1020 prints and machines a high-temperature aerospace tool for ST Engineering MRAS, a global leader in manufacturing complex aerostructures, including nacelle systems and specialized airframe components.
 
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

See us Live:
We will next be printing a double-sided RTM mold for an underwater tidal turbine blade each day of the event LIVE at JEC 2025 in Paris, France in the LIVE Demo Area on March 4th-6th, 2025 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.
LSAM Info Request
 

Learn More About LSAM

LSAM 1540

LSAM 1540 Shown

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IMTS 2024 Recap

Posted by Duane Marrett on Wed, Sep 18, 2024

Tags: Thermwood, Trade Shows, IMTS, LSAM, LSAM Additive Printers, LSAM AP, CLA, 2024, Recap

Highlights from the recent IMTS show held in Chicago!

IMTS 2024 Recap

It was a pleasure to showcase our innovative technologies, including the LSAM (Large Scale Additive Manufacturing) Additive Printer 510, which printed live, high-temperature (350°F) autoclave-capable aerospace tooling throughout the event!

Each day, we featured a different high-temperature material from leading 3DP material providers. Two tools were printed daily, each tool weighing 215 lbs and printed in 5 hours.

Purdue CMSC on hand at IMTS
We were also proud to highlight our collaboration with Purdue University’s Composites Manufacturing & Simulation Center (CMSC). The printed autoclave tool incorporated Purdue’s ADDITIVE3D simulation process to predict and compensate for shape changes due to residual stresses, interlayer bonding and deformation. Full scale tool samples showcasing vacuum integrity, surface quality and part precision were displayed for attendees.

Cut Layer Additive (CLA) Featured at IMTS

In addition, we featured our Cut Layer Additive (CLA) manufacturing process, a cutting-edge approach for creating tools, patterns and molds using sliced layer lamination. CLA enables the use of materials that are not 3D-printable and integrates features for vacuum, coolant and assembly – representing the future of mold manufacturing.

For More Information

If you’d like a closer look at our capabilities, we invite you to visit our complete demonstration center in Dale, Indiana (either in person or virtually).  Please contact us at sales@thermwood.com or call 1-800-533-6901 to arrange a personal demonstration.
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Sneek Peak: Printing Process on a Thermwood LSAM 1020 for Naval Surface Warfare Center

Posted by Duane Marrett on Fri, Jul 12, 2024

Tags: Demonstrations, LSAM, Naval Surface Warfare, LSAM 1020

Sneek Peak: Printing Process on a Thermwood LSAM 1020 for Naval Surface Warfare Center 

We're excited to share a sneak peek into our latest project - the advanced printing process using the Thermwood LSAM 1020 for the Naval Surface Warfare Center. Stay tuned for more updates and detailed insights coming your way soon!
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.
LSAM Info Request
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