Thermwood Develops New Vertical Tech for Large Format 3D Printing

Indiana-based Thermwood Corporation is the oldest manufacturer of highly flexible 3 and 5 axis CNC routers, and entered the 3D printing industry five years ago with a unique hybrid machine. Since then, it’s introduced, and continued improving upon, its Large Scale Additive Manufacturing (LSAM) systems [1]. These machines have both 3D printing and trimming capabilities, and are obviously used for making really big parts, like thermoplastic composite molds and tooling, for a variety of industries, such as aerospace, automotive, defense, government, marine, and military [2]. Users have 3D printed parts that stand over 20 feet tall and weigh up to 50,000 pounds on Thermwood’s larger LSAM machines, using the company’s patented Vertical Layer Print (VLP) technology.

Understanding Vertical Layer Print (VLP) Technology

Instead of printing on a horizontal plane, VLP prints on a vertical one, which makes it possible to fabricate much taller parts than prints with horizontal layers could accomplish [3]. This fundamental shift in printing orientation addresses critical limitations in large-format additive manufacturing. Traditional horizontal layer printing faces significant challenges with tall parts due to gravitational forces, material slumping, and the sheer volume of support material required. VLP eliminates many of these issues by building layers vertically, where gravity actually assists in maintaining part stability.

But now, Thermwood has announced that it has successfully demonstrated a new approach to large-format 3D printing with this technology. This advancement represents not just an incremental improvement, but a paradigm shift in how industrial-scale 3D printing can approach complex, large-part manufacturing challenges.

The Engineering Behind LSAM Systems

Moving gantries, high walls, and a fixed table are the typical features of Thermwood’s LSAM 3D printing systems, and when vertical printing is required for a tall part, a vertical moving table is used, which is supported by stainless steel belts that slide right on top of the main fixed table [4]. This sophisticated engineering solution allows for unprecedented flexibility in part geometry and size.

However, Thermwood released its MT last year, which is a less expensive LSAM printer with a moving table and fixed gantry but the ability to trim on the same machine. Just like the larger LSAM systems, parts are 3D printed at high speed and then machined to their final shape and size once they’ve cooled [5]. This hybrid approach combines the speed of additive manufacturing with the precision of subtractive processes, making it ideal for applications requiring tight tolerances and excellent surface finishes.

The Revolutionary New VLP Approach

To achieve vertically 3D printed tall parts on the LSAM-MT, the machine would need what the company referred to in a press release as a “fundamentally different approach.”

Thermwood’s new VLP approach prints parts on a support structure, which rides along on the moving table but is fixed in place to the back. The back of the main table features a second 5′ x 10′ print table that’s been vertically mounted, and as the part continues to get larger, the moving table pulls it onto a support structure [6]. This innovative mechanical solution creates a dynamic printing environment where the part essentially “grows” horizontally while being built vertically—a counterintuitive yet brilliant engineering solution.

This process allows the LSAM-MT 3D printer to fabricate parts that are up to 5′ x 10′ x 10′ (ZXY axes). It reminds me somewhat of a much larger version of conveyor belt 3D printers, though as far as I’m aware, those allow for long parts but don’t ensure vertical 3D prints [7]. The key difference lies in the vertical orientation and the integration of support structures that enable true large-format vertical printing.

Material Validation and Testing

In order to validate its new VLP process, the company printed parts out of low- and high-temperature thermoplastics. This comprehensive testing approach ensures that the technology is robust across various material classes and applications.

The first of these parts was made using carbon fiber reinforced ABS, often the choice for parts like fixtures, foundry patterns, industrial tooling, and structural components that operate at or right above room temperature [8]. Carbon fiber reinforcement significantly enhances the mechanical properties of ABS, including strength, stiffness, and thermal stability, making it ideal for demanding industrial applications.

The second high temperature part Thermwood built using the new approach weighed in at 1,190 pounds—the limit for a moving table system. It took just shy of 17 hours to complete and was printed out of a Techmer blended 25% carbon fiber reinforced PSU/PESU material, which, along with PEI, is used most often for tooling and molds that work at higher temperatures, typically with pressure and vacuum in an autoclave [9]. This high-performance material demonstrates the system’s capability to handle engineering-grade thermoplastics under demanding manufacturing conditions.

Industrial Applications and Benefits

The implications of Thermwood’s VLP technology extend far beyond mere size capabilities. Large-format 3D printing with VLP offers several critical advantages for industrial applications:

• Reduced Material Waste: VLP significantly reduces the need for support structures compared to horizontal printing of tall parts, lowering material costs and post-processing time.
• Improved Mechanical Properties: Vertical layering can produce parts with different directional properties, potentially advantageous for certain structural applications.
• Faster Production Times: The ability to print larger parts in a single build eliminates the need for assembly or joining of multiple smaller printed components.
• Enhanced Geometric Freedom: VLP enables geometries that were previously impossible or impractical with traditional horizontal layer printing.

Comparison: VLP vs. Traditional Horizontal Printing

Aspect	Vertical Layer Print (VLP)	Traditional Horizontal Printing
Maximum Part Height	Up to 40 feet	Typically 1-3 feet
Support Material	Minimal required	Extensive for tall parts
Gravity Effect	Assists stability	Can cause slumping/sagging
Build Speed	Similar to horizontal	Variable
Surface Finish	Different directional texture	Consistent horizontal layers
Material Options	Wide range (ABS, PSU/PESU, PEI)	Similar range
Part Weight Capacity	Up to 50,000 lbs	Limited by build plate

Thermwood LSAM Model Comparison

Feature	LSAM (Standard)	LSAM-MT (Moving Table)
Configuration	Moving gantry, fixed table	Fixed gantry, moving table
VLP Capability	Standard vertical moving table	New support structure approach
Max Part Size (VLP)	Up to 40 feet tall	5′ x 10′ x 10′
Weight Limit	Up to 50,000 lbs	1,190 lbs (moving table limit)
Cost	Higher	More affordable
Trimming Capability	Yes (integrated)	Yes (integrated)
Ideal Applications	Very large aerospace/defense parts	Large tooling, molds, fixtures

Technical Advantages and Limitations

Not only do Thermwood’s LSAM 3D printers have practically no weight limitations, but they can also print large parts that are able to maintain “vacuum to aerospace standards” without having to add a secondary coating [10]. This capability is crucial for aerospace and defense applications where surface integrity and vacuum-tight seals are mandatory. The ability to produce parts that meet these standards directly from the printer eliminates costly secondary processing steps and reduces the risk of introducing defects during post-processing.

Now, with its new and improved VLP approach, the company is building and delivering large-scale 3D printing systems that are actually up to 40 feet long. This represents a significant milestone in the commercialization of large-format additive manufacturing technology.

However, it’s important to note that VLP technology does have some limitations. The orientation may not be suitable for all part geometries, and certain applications may still benefit from traditional horizontal printing. Additionally, the mechanical complexity of VLP systems can increase maintenance requirements and initial investment costs. Despite these considerations, for applications requiring large, tall parts with structural integrity, VLP offers compelling advantages.

Market Impact and Future Developments

The introduction of enhanced VLP capabilities for the LSAM-MT model positions Thermwood competitively in the large-format additive manufacturing market. This technology addresses a critical gap between expensive, massive-scale systems and more limited mid-size printers. By enabling significant VLP capabilities on a more affordable platform, Thermwood is democratizing access to large-format vertical printing.

Looking forward, continued development in VLP technology will likely focus on expanding material options, improving print speeds, and further increasing size capabilities. Integration with Industry 4.0 technologies, including IoT sensors and AI-driven process optimization, represents another promising direction for the technology’s evolution.

Conclusion

Thermwood’s continued innovation in Vertical Layer Print technology demonstrates the rapid advancement of large-format additive manufacturing capabilities. The new VLP approach for the LSAM-MT system represents not just an engineering achievement, but a practical solution that brings large-scale vertical printing within reach of a broader range of industrial applications. As industries increasingly turn to additive manufacturing for producing large, complex parts, technologies like VLP will play a crucial role in enabling new possibilities and redefining what’s possible in 3D printing.

Frequently Asked Questions

Sources:

1. Thermwood Corporation – LSAM Overview, thermwood.com
2. 3DPrint.com, “Thermwood Enters 3D Printing Industry,” 2015
3. Thermwood Corporation, “Vertical Layer Print Technology” Technical Whitepaper
4. Thermwood LSAM System Specifications, thermwood.com
5. 3DPrint.com, “Thermwood LSAM-MT Introduction,” 2019
6. Thermwood Corporation Press Release, “New VLP Approach for LSAM-MT,” 2020
7. 3DPrint.com, “Conveyor Belt 3D Printing Technology Comparison”
8. Techmer PM, “Carbon Fiber Reinforced ABS Material Data Sheet”
9. Techmer PM, “PSU/PESU High-Temperature Material Specifications”
10. Thermwood Corporation, “Aerospace Quality Standards for Additive Manufacturing”

(Source/Images: Thermwood Corporation)

Frequently Asked Questions