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An all new technology for large scale 3D printing of thermoplastic polymers. Large industrial additive manufacturing machines that print and trim on the same machine. Standard LSAM closed configuration These are near net shape additive manufacturing systems that offer both print and trim on the same machine. They are configured with a fixed table, high walls and a moving gantry or gantries. Doors on each end enclose the machine so they can be built to meet European CE requirements.

The model number , and , denote the table size in feet 10’x10′, 10’x20′ and 10’x40′. Model numbers and denote the table size in feet 15’x20′ and 15’x40′. Although Thermwood is routinely building LSAMs in 40 foot lengths, even longer machines are possible, although nothing longer than 40 feet has been built to date.

The has a single control with both the print and trim heads mounted on a single moving gantry. It can both print and trim but not at the same time. The and larger machines have dual controls and dual gantries, one for print and one for trim. With these machines, it is possible to print one part on one end of the table and trim another on the other end at the same time.

Machines and larger can be equipped with a Vertical Layer Print System, allowing parts to be printed on a moving vertical table that are as tall as the machine table is long. LSAM MT open configuration This machine is configured with both a print and trim head on a single fixed gantry mounted over a moving table.

Like the above, this system can both print and trim, but not at the same time. The moving table is 10’x12′ with a 10’x10′ working area. The additional two foot of table length is for mounting an optional Vertical Layer Print Table, allowing parts that are up to ten foot tall to be printed vertically.

Print and trim heads on all LSAM machines are the same. Because of the open table configuration, the MT cannot be built to meet CE requirements. Both the above and the MT are available as «Print Only» machines for those who already have adequate trimming capability. As with all LSAM systems, they can process at temperatures up to degrees Celsius, which works with virtually all composite polymers available today.

Choice of configuration depends on several factors, fitting it existing factory floor space is one factor. The weight of the heaviest part you may want to print may be another factor. Systems come standard with a single servo table drive which can accommodate parts that weigh up to about 1, pounds. The 10 foot wide table can be equipped with an optional second table drive increasing the maximum weight capacity to 2, pounds. The final factor is Vertical Layer Printing. If you need taller parts, you may be able to print them by lying the part down and printing vertically.

It can print parts up to 10 foot tall. LSAM additive Printers use the exact same print head mechanism as all the other, including the largest LSAM Systems which means that they produce the same amazing print quality that has made LSAM the leader in large scale additive printing. They also use the same highly advanced Ultra 6 control with all its exclusive, patented print features and capability.

For installations that print a wider variety of materials, a dual hopper dryer is available as an option. An enclosure that surrounds the machine is also available.

The machine with the full enclosure can also be built to meet European CE standards. This is an exciting new system that automates the print process to easily 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 best temperature for bead fusion for that particular polymer. LSAM pronounced L-Sam represents the industry leading technology for large scale 3D printing of thermoplastic polymers.

LSAM utilizes unique patented technology to produce the highest quality printed structures available. LSAM uses the «Near Net Shape» approach to part production where the part is first printed at high speed slightly larger than needed, then trimmed to the final size and shape. This is the fastest, most efficient method of 3D printing large structures. With LSAM, both printing and trimming can be done on the same machine. LSAM can process parts from virtually any thermoplastic composite material including high temperature materials that are ideal for molds and tooling that must operate at elevated temperatures.

LSAM’s unique printing system produces parts that are solid, fully fused, vacuum tight and virtually void free. LSAM is intended for serious 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.

LSAM prints a large bead at room temperature in a process which is essentially an exercise in controlled cooling. Polymer cooling and not print head output determines print speed. Polymer cooling determines how fast you can print each layer. Print head output determines how large a part you can print in the layer time available. LSAM print heads are available that can print well over pounds per hour which means really large parts are possible. Large print beads plus Thermwood’s patented compression wheel create solid, fully fused, virtually void free printed structures that can sustain vacuum in a pressurized autoclave at elevated temperature without the need for problematic add-on coatings.

Parts are printed on a patented Bead Board, virtually eliminating cooling stresses and part warping. The compression wheel not only totally fuses layers together but also generates highly precise print bead dimensions, measured in thousandths of an inch. A Different Process. LSAM machines are large, robust industrial structures built from steel plate using slot and tab construction, resulting in an order of magnitude higher strength and stiffness than typical structural steel machine construction.

All welded structures are fully annealed using licensed technology originally developed by NASA, resulting in an even stronger, stiffer machine. LSAM machines have dual gantries, operating over a fixed table, and are available in configurations from 10 foot wide by 20 foot deep up to foot in length. Linear motion is laser aligned and compensated on all axes and the entire machine is volumetrically compensated throughout its entire working envelope for superior accuracy and performance.

LSAM provides both print and trim on the same machine and can print both horizontally and vertically. LSAM is a complete, fully engineered system, ready to run – with all the accessories and ancillary equipment included.

Traditional plastic extruder screws, designed for steady state operation, do not work for additive manufacturing. In fact, any extruder available today, by itself, will not work for additive manufacturing because of surging. LSAM uses a combination of a patented extruder screw design and a polymer melt pump to overcome these basic limitations.

This approach also means you do not need to change screws to process different polymers. LSAM can process virtually all materials with the same screw and melt pump. A changeable Melt Core means you can, on the same machine, increase print head throughput for really large parts. Parts can be printed either in the traditional horizontal orientation or, with an optional vertical layer print system, they can be printed vertically, allowing parts to be printed that are as tall as the machine table length.

This patented extrusion screw and barrel does not function like a traditional plastic extruder where most of the heat comes from shear action of the rotating screw. Screw speed is constantly changing in Additive Manufacturing, so the traditional approach means uneven heat.

Since friction between the polymer and screw geometry is not the major source of heat, the screw does not need to be changed to process different polymers. Precise print bead dimensions, measured in thousandths of an inch, are an absolute necessity for really quality printed structures. This is just not possible with a traditional extruder.

A common problem with plastic extruders, even in steady state operation, is uneven output flow, called surging. LSAM outputs flow from the extruder into a polymer melt pump.

This servo driven, fixed displacement pump precisely meters the heated polymer to the nozzle, forming a precise, consistent print bead. The LSAM control is based on Thermwood’s incredibly powerful CNC control, providing unique functions to make the print process easier and more capable. Temperature control is integrated, so when you load a polymer profile, all the parameters for that polymer, including zone temperatures and pressure limits are set automatically. The control automatically synchronizes output of the melt pump to machine speed to insure absolutely perfect bead dimensions regardless of machine speed, acceleration or deceleration.

Through a patent pending process, the control automatically synchronizes the speed of the extruder screw to the output of the melt pump, which is critical to proper operation.

The control orients the compression wheel to the direction of motion eliminating the need to program this function. The control can automatically adjust the print speed to maintain a consistent layer print time as print geometry changes, dramatically reducing the skill level needed to operate the machine.

The control also offers simple one-button operation of otherwise complex functions such as melt-start, stop-unload or qualifying a new material. Even with all the advanced capability LSAM is really easy to operate. Thermwood has already received numerous patents on these revolutionary developments and many more are in the works. In addition to the projects shown on this web site, 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. Video for Large-Part Production.

Plastics machinery and Manufacturing June 28, – Thermwood introduces larger 3-D printers. Aerospace Manufacturing May 13, – At the heart of innovation. Composites in Manufacturing March 10, – Thermwood unveils new thermal sensor layer automation system.

Composites World November 2, – Large-format additive manufacturing. DesignBoom October 25, – Thermwood 3D-prints a hull mold for a foot long yacht. Composites in Manufacturing October 23, – A new approach to 3D printing a yacht hull mould. Production Engineering Solutions September 18, – Thermwood partners on 3D printed tool with significant cost savings. Composites in Manufacturing November 12, – Partners successfully compression mould parts using printed tooling.

Call Thermwood! Composites World May 23, – Tooling technologies positioned for speed, control. Composites World February 15, – Thermwood and Bell collaborate on 3D-printed helicopter blade mold. The Additive Report February 7, – 3D printer helps launch new line of boats.