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.
LSAM - Large Scale Additive Manufacturing
Large industrial “Near Net Shape”, composite additive manufacturing machines that can print and trim on the same machine.
LSAM - Large Scale Additive Manufacturing
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 1010, 1020 and 1040, denote the table size in feet 10'x10', 10'x20' and 10'x40'. Model numbers 1520 and 1540 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 1010 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 1020 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 1020 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 1010 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 1010 above and the MT are available as "Print Only" machines for those who already have adequate trimming capability.
LSAM Additive Printers
LSAM Additive Printers are "Print Only" systems built around Thermwood's 40mm LSAM print head offering relatively large, highly capable machines at an attractive price point. As with all LSAM systems, they can process at temperatures up to 450 degrees Celsius, which works with virtually all composite polymers available today.
LSAM Additive Printer Brochure
These systems are a single gantry, moving table configuration and are available in two table sizes, 5’x5’ and 5’x10’. The 5’x10’ table is available in two configurations, 5’ wide with 10’ of front to back motion and 10’ wide with 5’ of front to back motion. 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 1,000 pounds. The 10 foot wide table can be equipped with an optional second table drive increasing the maximum weight capacity to 2,000 pounds.
The final factor is Vertical Layer Printing. All LSAM Additive Printers can print parts up to four feet tall. If you need taller parts, you may be able to print them by lying the part down and printing vertically. The only Additive Printer that supports Vertical Layer Printing is the 5 wide 10 foot deep version. It can print parts up to 10 foot tall.
The specially designed, highly rigid tab and slot, structural steel gantry also incorporates a fume extraction system that pulls print fumes through specially designed activated charcoal filters to remove them and “sweeten” the air.
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.
The systems come standard with a single hopper polymer dryer for applications that don’t change print material very often. 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.
What is LSAM?
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.
Part printed on LSAM's Patented "Bead Board" 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 500 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.
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 100 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.
3D Printing in process at Local Motors by LMI Knoxville, TN Microfactory
Trimming in process at Local Motors by LMI Knoxville, TN Microfactory
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.
Polymer Drying System
Dual Polymer Drying Hoppers
Fume Extraction
Chip Collection
Dual Liquid Cooling System
Vacuum Conveyor
Impact Resistant Trim Head
2 Ton Part Hoist and Gantry Mounts
Thermographic Camera & Software
Tool Measurement & Compensation
An Extruder Screw That Works Differently
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 patent pending design using special steel alloys supports processing temperatures of 450°C (Approx. 850°F) allowing the processing of high temperature polymers ideal for autoclave tooling.
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.
In the LSAM extruder, more than 60% of the heat comes from the heated barrel and not the screw, so polymer heating is more even.
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.
An Integrated Polymer Melt Pump
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.
High Temperature Capability
Ceramic heaters plus special alloys support print temperatures to 450 C.
Temperature-Controlled Compression Wheel
Changeable Melt Core
Printing Head Options
LSAM systems can print in three positions. Each print orientation has advantages and liimations for a particular part design. Offering all three on the same machine, means maximum print flexibility. All print orientations use the complete LSAM print head.
Horizontal Layer Printing (HLP). Standard printing from the machine table.
Vertical Layer Printing (VLP) option. Vertical Layer Printing allows parts to be printed that are as long as the machine table.
Angle Layer Printing (ALP) option. Angle Layer Printi8ng is the ability to print at a 45 degree angle.
Based on Thermwood's SuperControl
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.
LSAM uses Thermwood's SuperControl, which is one of the most capable, flexible and powerful controls in existence.
Integrated Temperature Control
LSAM has integrated temperature controls to monitor and adjust real-time temperature.
Automatic Process Functions
Also Includes:
Polymer Profiles
Motion and Print Synchronization
Extruder to Melt Pump Synchronization
Automatic Compression Wheel Orientation
Layer Time Control
One area that has been historically weak in large scale additive manufacturing has been the lack of truly professional slicing software specifically for the "Near Net Shape" process. To address this, Thermwood has developed a true "Near Net Shape" CAD slicing software that works within Mastercam and provides feature rich operation. With the ability to coordinate effortlessly with the LSAM machine and control, it accepts solid, surface, mesh or 2D geometry in every major CAD software format.
It offers powerful programming capability including boundary layers in any, or even variable, thickness, solid or sparse infill, stand-alone surfaces and free-form infill.
Incredibly complex parts can be programmed by separating them into individual structures and printing them concurrently either connected to or inside one another.
The software automatically adjusts for unique printing characteristics of the machine so the programmer doesn't need to deal with these complexities.
It adjusts the width of more than two beads printed side by side.
It compensates for corner pullback caused by the motion of the compression wheel.
Corner pullback compensation works by creating a tangent arc motion moving towards the outside of the corner, starting back at the point where the wheel stops on the bead, and then travels outward by the amount that the bead gets drawn in when the wheel rolls back onto the bead.
PESU print with corner pullback applied.
Posts a finished program ready to print.
- LSAM printed parts are fully fused, solid, and void free.
- LSAM printed tools sustain vacuum in an autoclave without an external coating.
- Large parts cannot delaminate, if printed within the isotherm temperature range for that polymer.
- The system can process virtually all thermoplastic polymers available today.
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 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.
This video details why LSAM has become the obvious choice for large scale additive systems actually operating in industry.
This book explores, in everyday language, all aspects of large scale additive technology used in industrial production today
LSAM customers seldom openly share financial results or other benefits resulting from their LSAM purchase, however, there have been some published articles that disclose this type of information.
3D Printing Media Network - Boeing 3D prints large-scale composite AM cure tool
3D Adept Media - In a program issued to Boeing, Thermwood's LSAM plays a key role in the development of a cure tool
Production Engineering Solutions - Thermwood partners on 3D printed tool with significant cost savings
3D Printing Media Network - Thermwood and General Atomics save $50K by 3D printing large-scale tool
(Videos) LSAM Machines and Features
A series of videos showing and explaining various LSAM machines and exclusive features.
Meet the Thermwood LSAM Additive Printer
Take a Tour of the Thermwood LSAM
Thermwood Adds Angle Layer Printing to its LSAM Large Scale Additive Systems
Thermwood Introduces the LSAM MT
Thermwood LSAM MT VLP (Vertical Layer Printing) Demonstration
(Videos) LSAM Projects and Collaborations
Information published about joint, large scale additive collaborative projects between Thermwood and various industrial, military and research organizations.
Al Davis Memorial Torch at Allegiant Stadium in Las Vegas.
The World's Largest 3D Printed Structure - Dimensional Innovations.
Made on an LSAM 1020
More Info on the Project
Thermwood and General Atomics Partner on Additive Tool with Significant Cost Savings
Thermwood and Bell 3D Print Helicopter Blade Mold
Thermwood LSAM 3D Printed Unclassified Scale Nose of a Submarine for the US Navy
Boeing 777X Aerospace Trim Fixture via Thermwood LSAM Vertical Layer Printing
(Videos) LSAM in Operation
A series of videos showing LSAM systems producing a variety of large scale parts.
Thermwood LSAM 1020 printing a Multi-Piece Foundry Pattern
Thermwood Validates Direct Additive Manufacturing of Yacht Hull Molds
Thermwood 1020 LSAM 3D Print/Trim Concrete Mold Timelapse
Thermwood LSAM 3D Printed Boat Hull Pattern
(Publications) LSAM Research Laboratory at Purdue University
