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Thermwood LSAM - Large Scale Additive Manufacturing

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SAM In the Press:

Additive Manufacturing (June 29, 2021) - Thermwood Releases Why LSAM? Video for Large-Part Production

Plastics machinery and Manufacturing (June 28, 2021) - Thermwood introduces larger 3-D printers

Additive Manufacturing (June 9, 2021) - Digital Demo - Why LSAM?

Composites in Manufacturing (June 2, 2021) - Thermwood expands LSAM product line

3D Adept (May 27, 2021) - There is a market for very large 3D printed parts

Additive Manufacturing (May 25, 2021) - Thermwood Adds Larger Printers to LSAM Product Line

Commposites World (May 24, 2021) - Why choose LSAM for large-format additive manufacturing?

Aerospace Manufacturing (May 13, 2021) - At the heart of innovation

Commposites in Manufacturing (April 23, 2021) - Thermwood expands LSAM product line again

3D Adept (April 21, 2021) - Thermwood further expands its large-scale additive manufacturing product line with new wide table flagship machines

3D Printing Media Network (April 20, 2021) - Thermwood expands LSAM product line yet again with larger LSAM 1540

Additive Manufacturing (April 16, 2021) - Purdue University to Establish Thermwood LSAM Research Laboratory

3DPrint. com (April 16, 2021) - Purdue University to Create Thermwood LSAM Research Lab for Large-Scale 3D Printing

Composites in Manufacturing (April 15, 2021) - University to establish Thermwood LSAM research laboratory

Composites World(April 15, 2021) - Purdue University to establish Thermwood LSAM research laboratory

3D Adept (April 14, 2021) - Purdue University and Thermwood: on the path to research into large-scale composite thermoplastic additive manufacturing

Woodworking Network (April 13, 2021) - CNC maker Thermwood and Purdue University team up on research lab

Aerospace Manufacturing (April 6, 2021) - Questions About LSAM with Thermwood's Scott Vaal

3D Adept (April 6, 2021) - Thermwood offers a smaller version of its hybrid large-scale additive manufacturing system

3D Adept (April 5, 2021) - Thermwood completes first LSAM 1010 system

Composites in Manufacturing(April 1, 2021) - Thermwood announces completion of the first LSAM 1010

3D Adept (April 1, 2021) - Thermwood completes first LSAM 1010 3D Printer with Fixed Table

3D Printing Media Network(March 18, 2021) - Meet the LSAM Additive Printer, new lower-cost system from Thermwood

3D Adept (March 17, 2021) - Back to basics: "Print Only", the ultimate goal of Thermwood's new LSAM system

Composites in Manufacturing (March 17, 2021) - Thermwood announces lower cost LSAM additive systems

JEC Composites (March 17, 2021) - Thermwood announces a major advance in additive print technology

Production Engineering Solutions (March 17, 2021) - Low cost, large scale industrial 3D printer launched by Thermwood

Composites World (March 16, 2021) - Thermwood advances LSAM capabilities with automatic print temperature monitoring

Manufactur3D (March 10, 2021) - Thermwood Announces a Major Advance in Additive Print Technology Thermal Sensor Layer Automation System

Composites in Manufacturing (March 10, 2021) - Thermwood unveils new thermal sensor layer automation system

3D Adept (March 10, 2021) - LSAM: Thermwood ensures automated print temperature control and enhances fusion between layers

Aerospace Manufacturing and Design (December 2, 2020) - A new approach: 3D printing a yacht hull mold

Composites World (November 2, 2020) - Large-format additive manufacturing

Manufactu3D (October 26, 2020) - Thermwood's New Approach to 3D Printing a Yacht Hull Mould

DesignBoom (October 25, 2020) - Thermwood 3D-prints a hull mold for a 51-foot long yacht

Composites in Manufacturing (October 23, 2020) - A new approach to 3D printing a yacht hull mould

3D Printing Media Network (October 22, 2020) - Thermwood 3D prints single hull mold for a 51-foot long yacht

Production Engineering Solutions (September 18, 2020) - Thermwood partners on 3D printed tool with significant cost savings

3D Printing Media Network (September 18, 2020) - Thermwood and General Atomics save $50K by 3D printing large-scale tool

Printer Chat (September 2, 2020) - New Low-Cost LSAM 3D Printer

3D Printing Industry (September 2, 2020) - Thermwood Demonstrates Vertical Printing Method with Low-cost LSAM MT 3D Printer

TCT Magazine (September 2, 2020) - Thermwood demos vertical layer large-format 3D printing process

3DPrint. com (September 1, 2020) - Thermwood Develops New Vertical Tech for Large Format 3D Printing

3D Adept Media (September 1, 2020) - New approach validates Thermwood's Large Scale Additive Manufacturing capabilities

3D Natives (September 1, 2020) - Thermwood develops a process for large format vertical 3D printing

Manufacturing News (September 1, 2020) - Thermwood Builds Massive Metalworking Machine to Increase LSAM Production

JEC Composites (August 31, 2020) - A Vetical Layer Print Additive Technology

Manufact3DMag.com (August 29, 2020) - Thermwood Demonstrates a New Vertical Layer Print Additive Technology for Large Parts

3D Printing Media Network (August 28, 2020) - Thermwood demonstrates a Vertical Layer Print tech with LSAM MT

Additive Manufacturing Media (August 19, 2020) - CGTech Extends Simulation to Thermwood LSAM (Includes Video)

Fabbaloo (March 25, 2020) - That Is A Large 3D Printer Enclosure!

3D Adept media (March 9, 2020) - Dennis Palmer on the possibilities of Thermwoods Large Scale Additive Manufacturing

Manufactur3D (March 6, 2020) - CGTech’s VERICUT Software to Simulate Thermwood LSAMs Additive & Hybrid Machining

3D Printing Media Network (March 5, 2020) - Thermwood introduces LSAM 1010 3D printer with enclosed configuration

3dPrinting Industry (March 4, 2020) - Vericut software used to simulate Thermwood's LSAM hybrid 3D Printers

AMTIL. com (February 13, 2020) - Thermwood introduces new LSAM model

3D Printing Media Network (November 18, 2019) - Thermwood presents new LSAM MT 3D printer

Technical Textile (November 18, 2019) - THERMWOOD, PURDUE FIND WAY TO COMPRESSION MOLD PARTS

Composites in Manufacturing (November 12, 2019) - Partners successfully compression mould parts using printed tooling

3D Printing Media (November 12, 2019) - Thermwood and Purdue lay groundwork for 3D printed compression mold tooling

3DPrint.com (November 12, 2019) - Thermwood & Purdue: 3D Printed Composite Molds to Make Compression Molding Parts

JEC Composites (August 20, 2019) - Air Force Research Laboratory, Boeing and Thermwood partner on low cost responsive tooling program

3D Printing Industry (August 13, 2019) - ARFL, BOEING, THERMWOOD APPLY LARGE SCALE ADDITIVE MANUFACTURING TO AUTOCLAVE TOOLS

Composites in Manufacturing(August 12, 2019) - US Air Force, Boeing and Thermwood partner on AM tooling programme

Additive Manufacturing(July 23, 2019) - Ascent Aerospace Invests in Additive Manufacturing

Composites World(July 18, 2019) - Ascent Aerospace invests in Thermwood LSAM machine

Aerospace Manufacturing(July 18, 2019) - Ascent Aerospace invests in new Thermwood LSAM Machine

3D Printing Media Network(July 17, 2019) - Ascent Aerospace buys LSAM composite 3D printer from Thermwood

PR Newswire(July 12, 2019) - Ascent Aerospace Invests in Additive Manufacturing

Additive Manufacturing(July 5, 2019) - Thermwood's Vertical Layer Printing Turns AM on Its Side

The Additive Report(July 3, 2019) - Hybrid additive/subtractive manufacturing machine produces large-scale parts

Fabbaloo(June 3, 2019) - Need A Very Large 3D Print? Call Thermwood!

Composites World(May 23, 2019) - Tooling technologies positioned for speed, control

3D Printing Media Network(May 14, 2019) - Kansas-based Dimensional Innovations acquires LSAM 3D printer for 'secret project'.

Tic Toc by Bloomberg(May 13, 2019) - 3-D printing Notre Dame Spire

JEC Composites(May 7, 2019) - Design by fire: Could a Kansas City company 3-D print the Notre Dame spire?

JEC Composites(March 1, 2019) - 3D printed helicopter blade mold

Bloomberg Businessweek(February 16, 2019) - An Ex-Marine Wants to Print Autonomous Vehicles for Your City

Composites World (February 15, 2019) - Thermwood and Bell collaborate on 3D-printed helicopter blade mold

Additive Manufacturing (February 11, 2019) - Thermwood and Bell 3D Print Helicopter Blade Mold

Marine Industry News UK (February 11, 2019) - 3D printer helps launch new line of boats

3D Printing Today Russia (February 11, 2019) - LSAM large format 3D printer prints rig for helicopter blades production

Print in 3D - Italy (February 9, 2019) - Thermwood prints in 3D the largest autoclave ever made

3D Printing Industry (February 8, 2019) - THERMWOOD'S LSAM MACHINES 3D PRINT 20 FOOT HELICOPTER BLADE MOLD FOR BELL

WKRN (February 8, 2019) - World's largest 3-D printer used to print cars in East Tennessee

The Additive Report (February 7, 2019) - 3D printer helps launch new line of boats

JEC Composites (February 7, 2019) - Thermwood and Bell 3D print helicopter blade mold

Aerospace Manufacturing (February 7, 2019) - Thermwood and Bell 3D print helicopter blade mould

3D Printing Media Network (February 6, 2019) - Thermwood and Bell 3D print 20 ft helicopter blade mold using LSAM

Composites World (January 11, 2019) - TAHOE Boats' T16 uses 3D printed tooling from Thermwood

Additive Manufacturing (January 14, 2019) - TAHOE Boats Newest Design Uses Thermwood 3D Printed Tooling

3Ders. org (January 17, 2019) - TAHOE Boats builds first hull with Thermwood 3D printed tooling

Additive Manufacturing (January 17, 2019) - Tahoe Boats Collaborates with Thermwood on 3D Printing for Boat Design

3D Print Media(December 5, 2018) - Thermwood validates direct additive manufacturing of yacht hull molds

Inside Composites(November 26, 2018) - Large-scale parts with Thermwood's LSAM

Additive Manufacturing(November 26, 2018) - Thermwood Collaborating with the Navy to Explore Additive Manufacturing Technology

Composites Media(November 15, 2018) - Thermwood collaborating with US Navy to explore additive manufacturing

Additive Manufacturing Today(November 15, 2018) - Thermwood Corporation and NSWCCD Announce Additive Manufacturing Collaboration

JEC Composites(November 15, 2018) - Thermwood collaborating with the Navy to explore additive manufacturing technology

Composites World(November 15, 2018) - Thermwood and US Navy Explore Additive and Additive Manufacturing for Ship Systems

3DPrinting. com(November 14, 2018) - Thermwood Unveils Vertical Layer Printing For LSAM Machines

Surface and Panel(November 14, 2018) - Thermwood Announces Vertical Layer Printing

Additive Manufacturing(November 14, 20188) - Thermwood Announces Vertical Layer Printing

Manufactur3DMagazine(October 12, 2018) - Thermwood Corporation 3D Prints a Massive 12-foot long 3D Printed Tool for Boeing

TCT Magazine(October 11, 2018) - Thermwood 3D prints and delivers 12-foot-long tool for Boeing

Plastics Insight(October 11, 2018) - Boeing collaborates with Thermwood to demonstrate VLP 3D printing technology

3D Adept(October 11, 2018) - Watch: Thermwood 3D prints 12 foot aircraft tool for Boeing 777X

3DPrinting Pro(October 11, 2018) - Boeing collaborates with Thermwood to demonstrate VLP 3D printing technology

3DPBites(October 11, 2018) - WATCH: THERMWOOD 3D PRINTS 12 FOOT AIRCRAFT TOOL FOR BOEING 777X

3DPulse(October 11, 2018) - BOEING PRINTS ON A 3D PRINTER MOLD TOOLING FOR THE GENERATION OF 777X AIRCRAFT

3D Print Home(October 10, 2018) - Thermwood and Boeing 3D print 12-foot-long single-piece tool for 777X program

Additive Manufacturing Today(October 10, 2018) - Thermwood Creates 3D Printed Tool for Boeing 777X Program

Additive Manufacturing (October 10, 2018) - Boeing and Thermwood Partnership to Demonstrate New 3D Printing Technology

JEC Group (October 10, 2018) - Boeing and Thermwood partnership to demonstrate 3D printing technology

3DPrintingIndustry. com (October 10, 2018) - WATCH: THERMWOOD 3D PRINTS 12 FOOT AIRCRAFT TOOL FOR BOEING 777X

3ders.org (October 10, 2018) - Thermwood and Boeing 3D print 12-foot-long single-piece tool for 777X program

Aero-mag.com (October 10, 2018) - Boeing and Thermwood Corp. form AM partnership

3druck.com(October 10, 2018) - Thermwood and Boeing make a large 3.66 meter 3D printed tool part for the 777X program

3Dprintingmedia.network.com (October 10, 2018) - Boeing and Thermwood partner to demonstrate new VLP 3D printing technology

CompositesWorld.com (October 10, 2018) - Boeing partners with Thermwood on 3D printed tool for 777X

3DPrint.com (October 9, 2018) - Thermwood and Boeing Make Large 3.6 Meter 3D Printed 777X Program Tooling Part

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'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

Thermwood secures 32 more patents to protect its Large-Scale Additive Manufacturing technology

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The Thermwood Corporation, a CNC machinery and large-format 3D printer manufacturer, has gained 32 new patents to further protect the technology behind its proprietary additive production systems. 

Specifically, the patents are said to relate to the firm’s Large-Scale Additive Manufacturing (LSAM) machines, which in their newest configuration, enable the creation of single-piece parts up to ten feet tall. Having first had the patents approved under COVID restrictions, Thermwood has now had their physical copies delivered, effectively providing a timely boost to its products’ IP protection.

“During COVID, we received electronic copies of patents that were granted, however, the official hard copies were withheld,” said Duane Marrett, Thermwood’s VP of Marketing. “A couple of days before Christmas 2021, we received a package containing the official hard copy of 32 additive manufacturing patents. This was certainly a one-day record for Thermwood and a welcome sight!”

“Although it is nice to have been granted these patents, it is even nicer to finally have the official hard copies in hand.”

Thermwood’s LSAM MT 3D printer. Photo via the Thermwood Corporation.

Large-Scale Additive Manufacturing 

Based in Dale, Indiana, Thermwood may be better known as a manufacturer of high-speed 3 and 5-axis CNC routers, but it has also established a strong 3D printing portfolio in the shape of its LSAM machines. Available in ‘MT’ and ‘Additive’ variants, each of the firm’s 3D printers feature a fixed table, high walls and a moving gantry, as well as closable doors that allow them to meet CE certification standards. 

However, while the company’s 1010 and 1020 systems have both print and trim-capable heads, its Additive machines are print-only, featuring a 40mm LSAM printhead that Thermwood says can process “virtually all composite polymers. ” 

One of the standout features of the firm’s 3D printers is their sheer scalability. Each unit is said to be capable of creating parts up to 1,000 pounds in weight and four feet tall, or 2,000 pounds and ten feet tall with its newer Vertical Layer Printing (VLP) systems. Developed late last year, VLP enables extrusion in vertical rather than just horizontal layers, unlocking the 3D printing of parts at unprecedented heights. 

“It is being used to produce a diversity of products including aerospace patterns, molds and tooling, heavy equipment foundry patterns, bus chassis, large valve body foundry patterns and trim tooling,” said Marrett. “It was even used to print the tallest 3D printed structure in the world, the 92-foot tall Al Davis Memorial Torch at Allegiant stadium in Las Vegas.”

Thermwood’s record-breaking haul 

Although Thermwood hasn’t disclosed the nature of the patents it was awarded during the pandemic, they’re understood to concern LSAM, a process it has made multiple filings to protect before. According to the firm itself, the technology is the most-used of its kind in the sector, thus the enhanced protection granted by its new patents should enable it to maintain what it sees as a market-leading position. 

In practise, LSAM has been deployed within numerous applications since it was first launched in 2016, varying from aerospace and transportation parts to those used in industrial or architectural settings. During 2018, for instance, Local Motors revealed that it had installed a 10’ x 40’ Thermwood machine, which it intended to use to 3D print parts for its ‘Olli’ autonomous electric vehicle. 

Thermwood’s technology has also proven to be extremely popular as an aviation production tool, with the firm first using it to create a 20-foot helicopter blade mold for Bell Helicopter Textron in February 2019, then deploying it alongside Boeing and the U.S. Air Force Research Laboratory to manufacture low-cost autoclave tooling later that year. 

When Thermwood did receive the physical copies of its patents in December 2021, it was the most it had ever gained in one go, making it a record-breaking day for the company, and moving forwards, Marret says it has further innovations up its sleeve.  

“Thermwood offers this unique patented technology on a wide variety of equipment,” concluded Marrett. “It includes a broad selection of machines, including single and dual gantry, fixed and moving table configurations, with both print-only and print-and-trim systems, from 5-by-10-foot to 20-by-60-foot print envelopes. They are working on even larger machines, but that’s for another day.”

A composite part being vertically printed using Thermwood’s VLP technology. Photo via the Thermwood Corporation.

Pushing large-format to the limit 

Although the colossal 3D printing capabilities of Thermwood’s machines are no doubt impressive, it’s far from the only firm operating in the large-format thermoplastic part production space. At Formnext 2021, BigRep launched its largest-ever pellet extrusion system with the PRO, complete with 1020 x 970 x 985mm build volume and fiber-reinforced composite filament-processing capabilities. 

Similarly, a year earlier, Titan Robotics released the 50″x50″x72″ build volume Atlas 3. 6 3D printer, a machine specifically built to be capable of producing huge prints at heights of up to 6 feet. Also designed to process pelletized feedstock, the machine was said at the time to be one of the largest of its kind on the market, and possess potential tooling, pattern, mold and functional part production applications.

More recently, Massivit 3D has also brought its Massivit 5000 and Massivit 10000 3D printers to market, systems with 1450 x 1110 x 1800mm and 1200 × 1500 × 1650 mm build volumes respectively. The latter is powered by the firm’s Cast-In-Motion (CIM) technology, a rapid four-step gel dispensing and casting process that’s said to expedite the mold and tooling production workflow for manufacturers.  

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Featured image shows Thermwood’s LSAM MT 3D printer. Photo via the Thermwood Corporation.

Tags Bell Helicopter BigRep Boeing Duane Marrett Local Motors MASSIVit 3D Thermwood Corporation Titan Robotics US Air Force Research Laboratory

Paul Hanaphy

Paul is a history and journalism graduate with a passion for finding the latest scoop in technology news.

High Temperature 3D Printing to the Masses / Sudo Null IT News

There is an impressive variety of thermoplastics that can be printed on consumer grade desktop 3D printers. But, despite this, most often users turn to polylactide (PLA) threads. This is not only the cheapest of materials, but also the easiest to work with. Its extrusion can already be carried out at a temperature of 180 °C, and good results can be obtained even without preheating the table. The disadvantage of PLA-printed objects is that they are relatively brittle and do not tolerate high temperatures well. For prototyping or printing low-stress components, PLA is great. However, many users quickly go beyond its capabilities. nine0003

Polyethylene terephthalate (PETG) is usually the next step. It is not much harder to work with compared to PLA, while it is more reliable and can withstand higher temperatures. In general, it is better suited for creating mechanically loaded parts. But if you need to make even stronger and more heat resistant parts, you can switch to acrylonitrile butadiene styrene (ABS), polycarbonate (PC) or nylon. And this is where the problems begin. These materials are extruded at temperatures over 250°C and closed chambers are recommended for best results. These printers are at the top of the budget range that hobbyists are willing to work with. nine0005

Industrial 3D printers like this one, the Apium P220, start at around $30,000. (PAEK, PEEK, PEKK). Components made from these plastics are suitable for aerospace applications as they can replace metal while remaining much lighter.

Such plastics need to be extruded at temperatures of around 400°C, and a sealed chamber is required for operation, the temperature in which constantly exceeds 100°C. The cheapest printers of this kind cost tens of thousands of dollars, and some models even cost six figures. nine0003

Naturally, not so long ago, the same could be said about all 3D printers. Once used only by well-equipped research labs, these machines now sit on the workbenches of hackers and hobbyists the world over. It is difficult to predict whether the same price-cutting race will start for high-temperature 3D printers, but the first steps to democratize the technology have already been made.

Engineering difficulties

Simply put, a machine that supports these so-called. "engineering plastics", you need to be a hybrid of a 3D printer and a stove. This, of course, is the main problem. The printer itself - of the type and quality we are accustomed to seeing on our desks - will not survive in such conditions. In order for a consumer printer to produce PEI and PEEK plastic parts, it needs to be seriously redesigned. This is exactly what NASA did with the LulzBot TAZ 4 in 2016. nine0003


LulzBot TAZ 4 redesigned to support high temperature printing

The first step was to design an insulated housing to fit the TAZ 4 and install a set of 35W infrared lamps for heating. Under such conditions, the printer's electronics would naturally overheat - so it had to be taken outside.

Stepper motors would also overheat. But instead of taking them out, the team at the Langley Research Center decided to build cooling shrouds on each of the motors through which the compressed air must circulate. nine0003

Like many desktop 3D printers, the TAZ 4 uses several printed components. Since they are ABS, they would quickly break down in a chamber designed to support PEEK. They were printed from PC, but even this material was not resistant enough for permanent use. In classic RepRap tradition, the team printed the last, third set of components on their most modified printer, in PEI plastic, commercially named Ultem.

Surprisingly, the team had no trouble changing the printer's nozzle to one that could extrude plastic at 400°C. The popular E3D-v6 extruder costs less than $100 and has been shown to be able to maintain this temperature. True, the team had to replace the thermistor with a better one, as well as edit the Marlin firmware so that it allowed it to reach high temperatures. For conventional printers, too high a temperature should cause an emergency shutdown. nine0003


Printing results from Ultem 1010 plastic on a redesigned LulzBot TAZ 4.

In the end, the NASA report indicated that the redesign of the LulzBot TAZ 4 was a complete success. They noted that an attempt to print PEI with infrared lamps turned off ended in failure - delamination and distortion of the model, which was to be expected. They did not specify the cost of the conversion, but given that at that time the TAZ 4 cost $2200, the entire project could cost 10 times cheaper than similar commercial proposals. nine0003

Starting from zero

A NASA experiment has shown that an existing desktop 3D printer can be converted to print with high-temperature engineering plastics, and quite inexpensively. But hardly anyone believes that this approach is the ideal solution. There are too many repetitive operations involved here, and NASA engineers had to abandon some of the decisions made by the LulzBot developers. Still, the experiment provided a valuable baseline for other projects built from scratch. nine0003

In September 2020, a team from Michigan Technological University demonstrated the Cerberus, an open-source, high-temperature 3D printer capable of creating items from PEI and PEKK, that costs as little as $1,000 to build. Without trying to adapt existing designs, the team started development from scratch, aiming for high temperature printing. All electronics are housed separately from the sealed chamber, which uses a kilowatt heating element to quickly raise the temperature in the chamber to operating temperature. nine0003

All stepper motors are also outside the chamber. Because of this, the kinematics become more complex than in desktop 3D printers, but Cerberus no longer requires a special motor cooling system.

Building a Cerberus is quite affordable for the aspiring hobbyist. It has a simplified circuit, ready-made control electronics based on the Arduino Mega 2560 and RAMPS 1.4, and the same E3D-v6 extruder as the TAZ 4. In addition, the team posted clear and detailed instructions for assembling the printer - this is not in the NASA report. meet. nine0003

Expanding possibilities

Whether it's NASA's redesign of the TAZ 4, or the new Cerberus-type circuits, it's clear that the technical capabilities of PEI and PEEK printing in the home workshop are already available for those who really need them. So far, it's not as easy as buying a $200 3D printer on Amazon, but if there is demand, cheaper machines based on the same principles will appear on the market. The situation is not much different from the current wave of affordable laser cutters hitting the markets in the past few years. nine0003


Fans all over the world print PPE

Is there a demand for such machines? A year ago, the answer might have been different from today. But in the fight against the coronavirus pandemic, there is a new demand for the rapid production of personal protective equipment (PPE) that no one could have foreseen.

print PPE that can be sterilized at high temperatures. The team believes that masks printed from PEKK can be reused rather than thrown away. nine0003

Components that can be printed and re-sterilized will obviously have other potential medical applications. A portable, low-cost machine capable of producing such components has the potential to save lives in places on the planet where supplies and equipment cannot be quickly accessed.

Critics of 3D printing have often said that the main disadvantage of these machines is that the reliability of the items they make rarely allows them to be used for anything other than rough prototyping. But when a $1,000 printer starts making aerospace-grade components, we seem to be moving toward a manufacturing revolution at an unprecedented pace. nine0003

13 BEST CONSTRUCTION 3D PRINTERS OF 2019


A 3D construction printer is a machine that can build houses by applying material (concrete) layer by layer. The paste type material used, in this case concrete or earth, is forced through the nozzle in layers to print buildings.
Concrete 3D printing in the construction industry saves time, effort and material when compared to traditional methods. However, it is important to note that 3D printers are not yet capable of creating a fully functional home, only the frame and walls can be created, other elements such as windows, electricity or plumbing must be installed separately. Concrete 3D printers can also be used to print bridges, benches, or simply outdoor decorations. nine0005 To provide a complete overview of the construction 3D printer market, we have listed the top 12 construction 3D printing solutions. Some of them are 3D printers already available for sale, while others are still in the prototype stage or provide 3D printing services for external structures.

HOW TO BUILD A 3D PRINTED HOUSE?

Construction 3D printers use extrusion technology. Some construction 3D printers are similar to FFF/FDM desktop 3D printers, only larger (gantry style), while others consist of a rotating mechanical arm. nine0005 In both cases, paste-type components such as concrete are used as the filament. The material is ejected from a special nozzle to form layers. In simpler (very) extrusion of pasta is like using a bag to dispense frosting on a cake.
The printer builds foundations and walls layer by layer. The base is literally the printer's build plate. However, some concrete 3D printers are used to 3D print brick molds. Once molded, the bricks are stacked on top of each other manually (or with a robotic arm). nine0005 Benefits of building 3D printing
• Eco-friendly : 3D printed houses can be built with sustainable materials. What's more, some construction 3D printers use solar energy and emit little CO2.
• Affordable: 3D construction printers can build affordable housing, providing great relief to people in poor areas or after natural disasters.
• Scalable: 3D construction printing reduces certain building costs. For example, the cost of 1 square meter of wall using traditional construction methods is approximately $75, while for an Apis Cor house 3D printer it is only $27. nine0005 • Efficient: Because materials are 3D printed on demand, machines produce less waste. In addition, 3D construction printers can complete the foundation of a house in less than a few days, while traditional construction methods take weeks or even months.
• Design flexibility: Curved walls and unique facades can be easily created with a 3D printer
Disadvantages of 3D construction
• Expensive initial investment: These 3D printers can sometimes cost up to a million dollars. nine0005 • Partially Built Houses : Only house frames are built. The 3D printing process is usually paused to manually install plumbing, wiring, and fittings.
• Rough Appearance : The exterior of most 3D printed houses is not as smooth as traditional houses.
• Lack of Certification: Construction sites are regulated by law and there are important safety standards that must be met, which can be difficult with 3D printing methods (different repeatability, dimensional stability, etc.). nine0005

CONSTRUCTION 3D PRINTERS: OVERVIEW


We divide construction 3D printers into three categories: house building 3D printers that you can buy, prototype concrete printers, and concrete 3D printing services.
Home 3D printers available

AMT printers

Pictured: AMT S-6044 Long and AMT S-300

), 11 x 31 x 80 (maximum)
• Material: Concrete / Clay / Gypsum
• Country: Russia

Equipment manufactured by AMT-SPETSAVIA - workshop and field portal construction 3D printers (COP-printers, Construction Objects Printing): and from small-format (for printing small architectural forms ) to large (for printing buildings up to 30 floors high). Productivity from 0.5 to 2.5 cubic meters per hour, management by 2 people. AMT printers are capable of printing with any kind of concrete, clay and gypsum.

BetAbram P1


• Assembly size : 1.6 x 8.2 x 2.5 m
• Material : Concrete
• Country : Slovenia
BetAbram is a small Slovenian team that has been working on building 3D printing equipment since 2012. Their flagship home 3D printer, the BetAbram P1, is currently in its second iteration and is available with additional printheads: basic, "Orto" for smoother layers, and rotatable for more design options.


COBOD BOD2


• Build size : 11.98 x 45.07 x 1.53 m
• Material : Concrete
• Country : Denmark
This design 3D printer is fast at up to 18 meters per minute. BOD2 is modular and can be adapted to various sizes. COBOD is a 3D Printhuset company.


Constructions-3D 3D Constructor


• Assembly size : 13 x 13 x 3.8 m
• Material : Concrete
• Country : France Their 3D Constructor machine is mobile thanks to its rubber tracks and fits in a 20ft shipping container for easy transportation from one construction site to another. nine0003

CyBe Construction CyBe RC 3Dp


• Assembly size: 2.75 x 2.75 x 2.75 m
• Material: Concrete
• Country: Netherlands This easy-to-use 3D printer is capable of reaching heights of up to 2.75 meters and only requires two people to operate.


ICON Vulcan II


• Build Size : 2.6 x 8.5 x ∞ m
• Material : Concrete
• Country : United States
ICON wants to revolutionize the construction industry with its Vulcan II printer. The whole process is designed to be user friendly with a tablet-based interface, and the ICON Lavacrete concrete mix is ​​optimized for easy printing.


MudBots Concrete 3D Printer


• Build Size : 1.83 x 1.83 x 1.22 m (Minimum)
• Material : Concrete
• Country : United States Concrete Printer is
Mudts005 USA. Their smallest model (approximately 1830 x 1830 x 1220 mm) is available for $35,000. Large build sizes are also available, reaching up to 30 meters in length. nine0005 According to MudBots, their 3D printers can print a small house in just 12 hours and cut costs by 70% compared to traditional building methods.

Stroybot2


Build Size : 10m x 15m x 6m
Material : Concrete
Country : United States
StroyBot, also known as the Rudenko 3D Printer, is a versatile mobile design printing system supplied as a build kit user. On average, he can print a 100 square meter house in 48 hours (walls only). nine0003


WASP Crane WASP “Infinity 3D Printer”


• Build size : Ø 6.3 x 3 m
• Material : Concrete / Earth materials
• Country : Italy
WASP Crane is an evolution of the previous WASP construction printer 12MT. This open source builder is modular and multiple Crane printers can work together on the same project, giving theoretically endless 3D printing possibilities.

Concrete printers job projects


Apis Cor 3D printer


• Assembly size : 8. 5 x 1.6 x 1.5 m
• Material : Concrete
• Country : United States
Apis Cor, a 3D based construction company Francisco and claims to be able to 3D print a house in less than 24 hours. Their Apis Cor printer is similar to a robotic arm and won first place in NASA's 3-stage 3D printing competition.


Batiprint3D 3D Printer


• Build Size : -
• Material : Concrete / Other
• Country : France
Batiprint 3D made headlines internationally when it completed the Yhnova 3D print shop in Nantes, France. Their 3D printer not only prints cement but also insulating foam, making it one of the most complete 3D building solutions.


S-Squared ARCS VVS NEPTUNE


• Assembly Size: 9.1 x 4.4 x ∞
• Material: Concrete
• Country: United States "4D printing", which aims to provide fast, reliable, environmentally friendly and affordable housing for poor areas. ARCS VVS NEPTUNE is one of the company's working models, but it will not be available for commercial sale.

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