Thermwood is proud to announce Audrey Jones and Mackenzie Tullis as our scholarship recipients for the Class of 2019.  Each 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. 

Audrey Jones is the daughter of Amie and Carl Jones of Ferdinand, IN.  She is a graduate of Forest Park High School. She has been involved in Community Impact, Student Council 9^th and 10^th grade, Key Club, 4H, and Golf. 

While at Forest Park she has received most improved Sophomore in Band, State Runner Up in Band, and MVP in Golf for 2 years. 

This fall Audrey will be attending IUPUI to study Clinical Lab Science.

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Mackenzie Tullis is the daughter of Mark and Melanie Tullis of Lincoln City, IN. She is a graduate of Heritage Hills High School.  She has been a member of Patriot Vibe. 

Mackenzie will be studying Dental Hygiene at the University of Southern Indiana.

Thermwood would like to congratulate all seniors of the Class of 2019 and wish them the very best in their future studies and endeavors! 

Dimensional Innovations now has Kansas City’s biggest 3-D printer

Overland Park-based Dimensional Innovations unveiled its newest piece of equipment, a $2.2 million 3-D printer and five-axis router that can make items 10 feet wide, 20 feet long and 5 feet high.

Produced by Thermwood, the equipment is known as a Large Scale Additive Manufacturing (LSAM) machine. It can produce huge components from reinforced thermoplastic composite materials. It’s the only one of its kind in the Kansas City area and one of only a handful currently in use in the U.S.

“Within the design, architecture and construction space, we’re not aware of anyone else who has this capability,” Dimensional Innovations CEO Tucker Trotter said. “There is not really someone else we can look to for examples on how to use this equipment, so we’re going to have to define that. It puts pressure on our team because there aren’t answers yet, but it also opens up incredible opportunities.”

Trotter said the purchase of the LSAM was driven by a secret project DI isn't allowed to discuss at this time, for production of a large-scale, iconic element. It had limitations on weight, needed to be prefabricated so it could be assembled in the field, had to be strong enough to meet wind load and had fire-proofing requirements.

“I went into the discussion for this project thinking it was really not a good fit for us,” Trotter said. “I couldn’t see how we could do it. But the culture at DI is so cool that we had people here who didn’t take no for an answer and spoke up saying they thought we could do it and here’s how. It started as a crazy idea, but now that we’ve got this equipment, I think it’s really going to advance who we are and how we’re seen by a lot of people.”

The company's growth made the addition possible. DI's business had outgrown its headquarters at 3421 Merriam Drive in Overland Park, so it moved the sign fabrication business to a new shop at 15500 W. 108th St. in Lenexa. That created room at the headquarters, allowing the company to buy the LSAM. It also is allowing DI to start building out about 50 new offices inside the headquarters, creating room to hire more designers and sales people.

DI has also been expanding into other cities, opening offices in Atlanta, Minneapolis and, most recently, Los Angeles.

“The smaller satellite offices have been low risk, and they’ve been very successful,” Trotter said. “We like that and will continue to do that. It puts our people and brainpower closer to projects.”

It also helps the company attract more talent, which in turn leads to more work.

About Dimensional Innovations

Dimensional Innovations - Dimensional Innovations is an award-winning, multi-disciplinary firm that creates dynamic, engaging and interactive solutions that bring brands to life.  DI helps businesses develop exceptional brand experiences to captivate and engage their target market. Works with clients that include 50,000 seat stadiums and history museums to create experiences customers will love. Focuses on the sports, corporate, student life and entertainment industries.

More Information on LSAM

LSAM is based on exciting new technology developed from an entirely new direction.

LSAM is intended for industrial production. It is not a lab, evaluation or demonstration machine, but is instead a full-fledged industrial additive manufacturing system intended for the production of large scale components.

Much of the technology used in Thermwood’s LSAM machines and print process is completely new. Thermwood has already received numerous patents on these revolutionary developments and many more are in the works. In addition to the projects already announced, many other exciting results that LSAM has already achieved are covered by non-disclosure agreements and must be kept secret. LSAM is truly state-of-the-art in the exciting new world of large scale additive manufacturing.

The Secret to LSAM Print Quality...A Different Process

Cut Ready - The First CNC That Doesn't Need a Programmer!

Cut Ready doesn’t need a programmer because there is already one inside the control. We call him “Artie”.

Despite the cute name, Artie is actually a cutting edge, artificial intelligence engine inside the Cut Ready control. You tell him what you want and he creates a program to make it. 

Artie has actually been hiding out behind the scenes in the Cut Ready control this whole time, but he has never made an appearance until now. He is the first A.I. dedicated to making your manufacturing life easier to handle.  While he is a CNC programmer and designer at heart, he also watches over your shoulder to make sure everything goes smoothly and efficiently. 

You tell him what you want and he creates a program to make it. Whether it is cabinets, doors, moldings or furniture, Artie will program it for you! 

These are not pre-programmed libraries. No part programs exist in the control until Artie creates them. 
He is already capable of programming tens of millions of unique products and is constantly learning how to make and do more and more new things.

Artie is easy enough that virtually anyone can work with him with little or no training. 
 

Cut Ready is currently available on two machines from Thermwood:

The Cut Center - requires neither a CNC programmer nor a trained machine operator. Artie moves beyond just programming to guide the operator through the entire production process real time. It is complete, fully contained with all the ancillary equipment smoothly integrated into a package that almost runs itself.  Pretty much anyone can run a Cut Center.

The Cut Ready 43 - is a lower-priced machine that doesn’t need a CNC programmer, but does require a trained and somewhat skilled machine operator.  With the Cut Ready 43 system, Artie offers help during the production process, but not quite to the extent that it does with a Cut Center.  

Cut Ready Series Machines Detailed Comparison 

More Info on the Cut Ready 43 with Artie Inside

The Cut Ready 43 is equipped with a 5 by 8 table, a 21-position tool changer and a high flow vacuum hold-down system (additional table sizes and options are available).

The Cut Ready 43 is intended to bring the magic of Artie to a lower-priced system. It features a full-sized vacuum table and, just like its big brother, doesn’t require a CNC programmer. Just like a Cut Center, it can help you quickly and easily create most products a cabinet shop would want to make without a CNC programmer (only operational training is required).

Since this is a CNC router at its core, you are free to program and operate it as a normal CNC router if you want, but the magic of Artie makes the Cut Ready 43 a whole new exciting experience!

For More Info on the Cut Ready 43, please click here.

The video below shows the powerful Cut Ready 43 machining a door and matching drawer front in MDF using diamond tooling. 

More Info on the Cut Center with Artie Inside

The Thermwood Cut Center is equipped with a 5'x10' table, easy sheet flipper, vacuum cups and a host of other software and equipment.  It is all designed to help you save time and money, using an easy to operate and sophisticated combination of software and machinery that you can feel confident in.  

We've taken the fear out of automation by combining our easy to use interface and years of experience in the industry to create a powerful tool that will allow you to focus more on your products, business, making money, and worry less about being intimidated by the technical details. It is complete, fully contained with all the ancillary equipment smoothly integrated into a package that almost runs itself.

The Cut Center is the ultimate in next generation CNC. 

Your time is money, and the Cut Center helps you save more of both.

For More Info on the Cut Center, please click here.

What Some of Our Cut Center Customers Are Saying...

The Thermwood Multi-Purpose 45 is a heavy-duty, high-performance three axis CNC router designed for real-world production.

Available in either single or dual spindles (with optional rotary axis), the Model 45 is used in the machining of composites, tooling boards, plastic sheets, aluminum, cabinets, solid wood, millwork, phenolic, display fixtures, nested based panels and much more.  

This versatile machine is available in a variety of table sizes and has enough standard features and options to get the job done.

Features of the Model 45:

• 12 HP HSD Spindle (3,000-24,000 RPM). Optional 18 HP Spindle
• 4 Position Bar Style Automatic Tool Changer. Optional 7 Position
• Optional Rotary Axis (accepts stock from 8" (200mm) in diameter and up to 56" (1.4m) in length)
• Fixed Steel High Flow Table with Moving Gantry (sizes from 5'x5' to 7'x12')
• Multi-Function Table (pod system capable) (Optional)
• At the Head Automatic Tool Changer (Optional)
• Extended Z Clearance and Stroke (Optional)
• Optional Pod System Available
• Optional Pause Mats Available
• Automatic Lubrication (optional)
• Automatic Tool Length Measurement (Optional)
• Three-Dimensional Laser Compensated Axis Alignment
• Control Nesting
• Siemens Intelligent Servo Drives Throughout
• QCore SuperControl
• Machine Training and Installation
• Free Lifetime Phone/Forum Support

Videos

Latest Cut Ready Update Summary

We are constantly adding new features and abilities to the Award-Winning Cut Ready Cut Center

With this latest update, we've added over 1,200 additional cabinet definitions, updated many cabinet images and expanded the information presented with the cabinet, added an informational Update section to Cut Ready, added varying depths to Shaker Doors and incorporated the ability for users to share left over off-fall between Cut Ready and CNC Mode. 

Over 1,200 Cabinet Definitions Added

Thermwood has added over 1,200 new cabinet definitions to Cut Ready, giving Artie (Cut Ready's A.I.) the ability to make a wider range of cabinet styles!  This batch of definitions focus on kitchen base cabinets for both frameless & face frame choices. Below are a few examples: 

Updated Images and Descriptions

We’ve also replaced lots of cabinet images to make choosing a cabinet easier, while also including valuable information:

Expanded Update Information

Finding out what is in each update just got easier, too.  Simply select the information button to learn what is in each update.

Varying Depths for Shaker Doors

Shaker Doors now have varying depths to choose from:

Easily Share Off-Fall Between Cut Ready and CNC Mode

Advanced users who currently switch between Cut Ready and CNC Mode can now easily share your left-over off-fall between the two modes.

About the Cut Center

The Thermwood Cut Center is an exciting alternative to traditional CNC routers for making a wide variety of products including cabinets, closets, furniture, doors, drawers and much more.  Just tell the machine what you what to make and it does it...it is that simple!  NO programming is required. 

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A joint venture program between Thermwood and Bell has pushed the limits of 3D printing, resulting in what Thermwood believes is the largest 3D printed autoclave capable tool ever made. 

The first half of an 18 foot helicopter blade mold that was 3D Printed in just over 3 hours

A common limiting factor within aerospace development programs is expensive, long-lead time tooling.  Bell, not being satisfied abiding by the industry norms, decided to reach out to Thermwood to help solve this challenge.

Video

The Challenge

Shortly after initial conversations with Bell, the Thermwood team offered an opportunity of a partnership centering around the capabilities of their new 60mm melt core technology.  The original challenge for quickly and affordably manufacturing large bond tooling seemed closer to reality than ever before. 

Bell responded to this opportunity in kind by providing Thermwood a model of a closed cavity blade mold measuring approximately 20 feet long, 14 inches wide and 17 inches high. 

The basic tooling requirements were as follows:

• Must to be printed in one continuous run for vacuum integrity
• Surface finish must be 32 RMS or better
• Tooling must be able to withstand 90 psi at 360°F. 
• Tight tolerances and features were also required to ensure proper mating of the two blade mold halves.

The Process

Upon receiving the model and requirements, the Thermwood team sprang into action. Utilizing their new 60mm melt core technology, they began to print the tool using TechmerPM’s 25% Carbon Fiber reinforced PESU (Polyethersulfone) in one continuous run. Working closely with Thermwood, Techmer has formulated this material specifically for LSAM additive printing.

The printable material has a Glass Transition Temperature of over 400°F and can easily survive common aerospace component cure cycles of up to 360°F, at 90psi. The combination of Techmer's new materials and Thermwood's printing technology, resulted in a print time of one tool half in just 3 hours 8 minutes and an “as printed” weight of 542 pounds.

Thermwood technicians claim the Techmer PESU material prints as easily as ABS, although at a much higher temperature, allowing quality autoclave-capable molds to be made from the high temperature polymer.

This extraordinary achievement was made possible by a new, larger melt core recently installed on Thermwood’s LSAM system at its Development/Demonstration Lab in Southern Indiana. The standard LSAM machine print head housing can be equipped with different capacity melt cores, each offering different minimum and maximum throughputs.

Continuous Cooling Print Process

With Thermwood’s room temperature “Continuous Cooling” print process, the cycle time for each layer is determined solely by how long it takes a particular printed polymer to cool to the proper temperature to accept the next layer.

Only by printing at the proper temperature can you achieve a totally fused, void-free printed structure that will maintain vacuum in an autoclave without a coating. The print head output determines how much material can be printed during the time it takes for the layer to cool. Bigger print heads mean larger parts, not necessarily faster layer to layer print time.

Thermographic view of the part being printed

The new 60mm melt core has a measured maximum output of 480 to 570 pounds per hour depending on the polymer being printed and can print over 100 feet of typical print bead (.830” x .200”) per minute. This high print rate, even when processing high temperature material, allows the print bead to be oriented along the length of the tool. This is desirable for Bell, who manufactures large composite parts, because thermal expansion is significantly lower in that direction, minimizing expansion and contraction of the tool with temperature changes.

Internal Printed Support Structure

Another interesting feature of this tool is that the internal printed structure supports the mold without actually contacting or touching the back side of the mold cavity. This means air can flow freely under the entire formed part in the autoclave, making the part curing process easier and more consistent. The ability to incorporate a complex internal design, such as this, is another major advantage of using additive manufacturing for this type of tooling.

3D printed internal support structures

Thermwood’s LSAM Print ^3D slicing software specifically supports programming of involved internal structures such as these.

Internal support structures in  LSAM Print ^3D slicing software

Bell Investigates Multiple Manufacturing Processes

Bell is continuing to investigate integrated technologies that support multiple manufacturing processes and tools.  The LSAM is capable of supporting printing processes as well as trim and drill processes to meet aerospace specifications.  Once printed, the team began to machine the bond tool half by utilizing the other aspect of the LSAM system.  The total machining time of the lower blade mold half was 40 hours.  

The completed bond tool was able to maintain Bell’s vacuum standards required for autoclave processing right from the machine, without the need for a seal coating. 

Part maintaining vacuum during extended testing

The part steadily holding vacuum during testing

Next Steps

The Thermwood team will print the second half of the blade mold, with the intention of having Bell cure a full molded blade within the final additively-manufactured bond tool, another first.  Further testing will be completed by both Thermwood and Bell teams on PESU printed molds, to continue innovating in this space. 

Final Thoughts

Thermwood believes recent LSAM technology advances such as Vertical Layer Printing and Changeable Melt Cores (coupled with polymers specially tailored for LSAM processing), are opening exciting new possibilities for additive production of even larger and more technically complex components.

More Information on LSAM

LSAM is based on exciting new technology developed from an entirely new direction.

LSAM is intended for industrial production. It is not a lab, evaluation or demonstration machine, but is instead a full-fledged industrial additive manufacturing system intended for the production of large scale components.

Much of the technology used in Thermwood's LSAM machines and print process is completely new. Thermwood has already received numerous patents on these revolutionary developments and many more are in the works.

LSAM is the Leader in Large Scale Additive Sales

In the last year, Thermwood's LSAM additive manufacturing systems were the clear market leaders in the sale of large scale 3D printing systems for thermoplastic composite materials, selling virtually all systems in the US during the year.

LSAM is truly state-of-the-art in the exciting new world of large scale additive manufacturing.

The Secret to LSAM Print Quality...A Different Process

Latest Cut Ready Update Summary

We are constantly adding new features and abilities to the Award-Winning Cut Ready Cut Center

With this latest update, we've added greater flexibility to Face Frame Bath Cabinets.  You now have more control when resizing these cabinets.  In addition, we've added several more, unique Bathroom cabinets as well.

New Bathroom Cabinet Additions Examples:

About the Cut Center

The Thermwood Cut Center is an exciting alternative to traditional CNC routers for making a wide variety of products including cabinets, closets, furniture, doors, drawers and much more.  Just tell the machine what you what to make and it does it...it is that simple!  NO programming is required. 

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