An all new technology for large scale 3D printing of thermoplastic polymers

LSAM ® - Large Scale Additive Manufacturing

Large industrial additive manufacturing machines that 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.
Available Table Sizes:
10' wide, with length capability up to 100'

  • Additive and Subtractive Gantries on the same machine
  • Standard Dual Dryer System
  • Standard Thermographic Imaging Camera
  • Working Envelope 10 feet (up to 100 feet available)
  • Standard Fume, Dust and Chip Extractor System
  • Siemens Intelligent Servo Drives Throughout
  • QCore SuperControl
  • Machine Training and Installation
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What is LSAM?

LSAM (pronounced L-sam) represents an all new technology for large scale 3D printing of thermoplastic polymers. While other large scale additive efforts attempt to scale up small, filament-fed desktop printer techniques, LSAM is, at its core, designed for additive manufacturing of large structures using a fundamentally different approach

LSAM is different. The print process is different. The machine is different. The print head is different. The control is different. The software is different and the resulting parts are different.

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.

Parts are printed on a patented “Bead Board”, virtually eliminating cooling stresses and part warping. 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. Print head output determines how large a part you can print. Polymer cooling determines how fast you can print each layer.

Parts are printed on a patented “Bead Board”, virtually eliminating cooling stresses and part warping. A patented compression wheel totally fuses layers together while generating highly precise print bead dimensions, measured in thousandths of an inch.

LSAM machines are built from steel plate using slot and tab construction

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.


LSAM provides both print and trim on the same machine

3D Printing in process at Local Motors by LMI Knoxville, TN Microfactory

LSAM provides both print and trim on the same machine

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.

 

 

 

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 450oC (Approx. 850oF) 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.

LSAM has an extruder screw that works differently.
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.

 

 

 

 
LSAM can print precise print bead sizes - somethying that is just not possible with a traditional extruder.

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 has 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

LSAM has an integrated polymer melt pump.

Ceramic heaters plus special alloys support print temperatures to 450 C.

 

Temperature-Controlled Compression Wheel

LSAM has an integrated polymer melt pump.
 

Changeable Melt Core

LSAM has an integrated polymer melt pump.
 

Print Both Horizontal and Vertical

LSAM printing horizontally.
 
 
LSAM printing vertically.

Based on Thermwood's Q-Core SuperControl

The LSAM control is based on Thermwood’s incredibly powerful Q-Core 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.

Based on Thermwood's Q-Core SuperControl.

LSAM uses Thermwood’s Q-Core SuperControl, which is one of the most capable, flexible and powerful controls in existence.

 

Integrated Temperature Control

LSAM integrated temperature control.

LSAM has integrated temperature controls to monitor and adjust real-time temperature.

 

Automatic Process Functions

LSAM automatic process functions
 

Also Includes:

  • Polymer Profiles

  • Motion and Print Synchronization

  • Extruder to Melt Pump Synchronization

  • Automatic Compression Wheel Orientation

  • Layer Time Control

Thermwood’s LSAM Print 3D is a true CAD slicing software that works within Mastercam. It accepts solid, surface, mesh or 2D geometry in every major CAD software format.

Thermwood’s LSAM Print 3D is a true CAD slicing software that works within Mastercam. 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.

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.

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 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.

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.

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.

PESU print with corner pullback applied.

 

 

 

 
Posts a finished program ready to print.

Posts a finished program ready to print.

LSAM is ideal for large parts
  • 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.

LSAM is based on exciting new technology developed from a new direction. Thermwood has already applied for 19 separate patents on various aspects of this new technology, several have already been granted and more will be coming as development continues. LSAM is truly “state of the art” in this exciting new world of Large Scale Additive Manufacturing.

LSAM In the Press:

3DPrintingMediaNetwork.com (July 3, 2018) - Local Motors installs massive LSAM composite 3D printer to manufacture autonomous Olli shuttle

3DPrintingIndustry.com (July 2, 2018) - World's Largest Composite 3D printer Installed by Thermwood at Local Motors to Make Self-Driving Vehicles

CompositesManufacturingMagazine.com (July 2, 2018) - Thermwood Installs World’s Largest Composite 3-D Printer at Local Motors

AdditiveManufacturing.com (June 13, 2018) - LSAM Speeds Production of Concrete Tooling

CompositesWorld.com (Dec 1, 2017) - Thermwood 3D Prints Large Boat Hull Pattern

3DPrintingIndustry.com (Dec 1, 2017) - Thermwood's LSAM Process Sets Sail With 3D Printed Hull Pattern

3DPrintingIndustry.com (Oct 23, 2017) - First Ever Polysulfone Mold For Chinook Helicopter Part Successfully 3D Printed

CompositesManufacturingMagazine.com (Oct 22, 2017) - Thermwood Creates Composite Helicopter Part made with Innovative 3-D Printing Technology

3DPrint.com (Oct 19, 2017) - Collaboration and 3D Printing Streamline Boat Production

Composites In Manufacturing (June 26, 2017) - Thermwood 3D Printed PPS Test Panel Maintains Vacuum Without Coatings

3DPrintingBusinessDirectory.com (June 19, 2017) - Thermwood Vacuum Tests 3D Printed PPS Panels Without Coatings

TCTMagazine.com (June 19, 2017) - Thermwood 3D Printed PPS Test Panel maintains Vacuum without Coatings

3DPrint.com (June 17, 2017) - Thermwood Demonstrates Effectiveness of LSAM with 3D Printed Carbon Fiber Parts

TCTMagazine.com (June 16, 2017) - Thermwood Tests 3D Printed Carbon Firbre-Filled PPS Panels Without Coatings

NetComposites.com (June 13, 2017) - Thermwood Enhances Additive Manufacturing Software

3DPrint.com (June 12, 2017) - Thermwood Adds New Features to LSAM Print3D Additive Manufacturing Software

3D Grenzenlos.de (June 10, 2017) - Thermwood stellt Update seiner LSAM Print3D Software vor (German)

AdditiveManufacturing.com (June 8, 2017) - Thermwood Adds Important New Features to LSAM Print3D Additive Manufacturing Software

TCTMagazine.com (June 8, 2017) - Thermwood Announces New Capabilities for LSAM Print3D Software

NetComposites.com (May 30, 2017) - Thermwood Unveils New 3D Print Head Design

3DAdept.com (May 29, 2017) - Thermwood's large-scale additive manufacturing machine improved

3DPrintingIndustry.com (May 26, 2017) - Thermwood Upgrades Large-Scale Additive Manufacturing machine with ton and a half toolhead

3DPrintingMediaNetwork (May 26, 2017) - Thermwood Introduces New Print head for Large Size LSAM 3D Printer

AdditiveManufacturing.com (May 25, 2017) - Thermwood Unveils New 3D Print Head Design

3DPrint.com (May 25, 2017) - Thermwood Introduces New Universal Print Head for LSAM 3D Printer

AdditiveManufacturing.com (Nov 30, 2016) - Thermwood Adds Thermographic Imaging to its Additive Manufacturing Machines

AdditiveManufacturingToday.com (Nov 29,2016) - Thermwood Adds Thermographic Imaging to its Additive Manufacturing Machines

prweb.com (Sept 29, 2016) - Thermwood Introduces LSAM: Large Scale 3D Additive Manufacturing Systems

NetComposites.com (Sept 20, 2016) - Thermwood Has Successfully Tested the 'Ultra High Output' PH50 Print Head on the LSAM

CompositesWorld.com (Sept 15, 2016) - Thermwood successfully tests composite thermoplastic print head on LSAM

WoodworkingNetwork.com (Sept 14, 2016) - Thermwood successfully tests ultra-high output PH50 3D print head

Engineering.com (Sept 12, 2016) - Hybrid 3D Printer-CNC Machine Offers a Cut Above the Rest

NetComposites.com (Sept 6, 2016) - Thermwood Offers 3D Additive Manufacturing Program with LSAM Machines

3Ders.org (Sept 1, 2016) - Thermwood introduces new massive LSAM 3D printers with CNC technology

3DPrint.com (Sept 1, 2016) - Thermwood Corporation Introduces LSAM: Large Scale Additive Manufacturing with a CNC Twist

WoodworkingNetwork.com (Aug 31, 2016) - Thermwood debuts large-scale 3D additive CNC machines

Videos

Thermwood LSAM 3D Printed Boat Hull Pattern


Thermwood 10'x20' LSAM 3D Print/Trim Concrete Mold Timelapse


Thermwood LSAM 10'x10' 3D Printing Two Parts Simultaneously


Thermwood LSAM Time-Lapse Video 3D Printing and Trimming Mold


Short Clip of Thermwood LSAM 3D Printing and Trimming Four Parts at Once