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

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

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

We offer the broadest range of LFAM (Large Format Additive Manufacturing) 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 be at a variety of upcoming shows in the next few weeks, and you can visit to learn more about LSAM.
Check us out next week at SAMPE 2023 in Seattle (booth E10), JECWorld 2023 in Paris starting on April 25th (US Pavilion, Hall 6, booth Q49) and printing live with #SABIC’s LNP™ ELCRIN™ WF006NiQ resin on an LSAM AP 510 at Rapid 2023 in Chicago starting May 2nd (booth #2418).

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!
Visit https://bit.ly/3GFE3RR to learn more about LSAM.

LSAM Examples

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.