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Thermwood develops large-scale additive manufacturing system

Thermwood Corp., a manufacturer of CNC routers, is developing large scale additive manufacturing (LSAM) technology that can perform both the additive and subtractive functions on the same machine. A high-volume thermoplastic printer can quickly create a part that is near net-shape that subtractive machining finishes to final shape.

The development effort initially validated MeltShape technology that promises enhanced control of layer shape and improved bonding between layers in large-scale additive manufacturing.

This patent-pending approach uses shaping wheels to shape, form, and compress hot plastic melt as it is extruded, ensuring that each new layer is the proper shape and thickness and that it bonds firmly to previously applied material. Thermwood engineers envision different shaping wheels imparting specific characteristics to the hot plastic bead.

Because layers are rolled together, rather than tamped together, air between layers is squeezed out during the additive process, so it is less likely to become trapped between layers. Initial testing produced virtually void-free walls, reducing the problem of trapped air delaminating layers during autoclaving.

The material used during startup testing was a 20% carbon graphite-filled ABS from Techmer ES, but Thermwood is considering other suppliers to test their materials.

The Thermwood machine is a full 6-axis system: five axes to position the head in any orientation and the sixth axis to align the shaping wheels to the machine motion direction. A software feature, tangential following, automatically keeps the shaping wheel aligned with the direction of machine motion without 6-axis programming, so a 5-axis CAD/CAM system can program machine motion. Because of its 5-axis head configuration, material can be applied at an angle or onto curved surfaces in addition to horizontal layers.

Thermwood’s initial test machine, which can print parts up to 10ft x 10ft x 5ft, is expected to be fitted with a 5-axis subtractive gantry trim system in the next few months.

Kevin Slusarz, American Kuhne vice president of process technology, assisted with the startup effort. American Kuhne, a Graham Group Co., supplied the custom extrusion system during testing on Thermwood’s development machine. Extruder controls are designed to network and integrate with the machine control.

“We are quite pleased to have a partner like American Kuhne as part of this development program,” says Ken Susnjara, Thermwood’s CEO. www.thermwood.com

ESPRIT CAM attracts 1,000+ visitors to EMO Milan exhibit

DP Technology, developer of ESPRIT CAM software, attracted more than 1,000 visitors to its exhibit at the EMO 2015 trade show in Milan, Italy, and generated 300 qualified leads.

“The response to our exhibit demonstrates the popularity of ESPRIT and that European metalworking companies are more concerned than ever with increasing productivity,” says Luca Ruggiero, DP Technology’s country manager, Italy.

ESPRIT 2015 provides improved features in intelligent machining, strategic machining, CAD-CAM data exchange, and Cloud-Enabled CAM.

Visitors to EMO received customized demonstrations at the ESPRIT booth and saw ESPRIT software in action on machine tools at the booths of Okuma, Citizen, Nakamura-Tome, EMCO, FFG, Tsugami, and Hurco.

Additionally, a new partnership between ESPRIT and machine-tools builder FFG was announced at EMO.

“ESPRIT is able to support more of our specifications than any other CAM software provider that we have worked with,” says Jürgen Reingen, head of development for FFG. “The customer support provided by DP Technology and resellers is also very knowledgeable, comprehensive, and prompt.” www.dptechnology.com; www.ffg-werke.com; www.okuma.com; www.marucit.com; www.emco-world.com; www.hurco.com; www.remsales.com; www.methodsmachine.com

Bodycote increases hot isostatic pressing capacity

Thermal processing services provider Bodycote is expanding its high pressure hot isostatic pressing (HIP) capability with the addition of a mid-range vessel to increase volume capacity.

The HIP system will be focused on high pressure developments in aerospace and advanced materials and will be capable of processing up to 2,000bar (30,000psi) and temperatures up to 2,000°C (3,632°F). This additional vessel is complementary to the company’s installed capacity across North America and Europe.

Bodycote has more than 50 HIP vessels of varying sizes in multiple locations. Processing capability can accommodate components up to 2m x 3.5m and weighing 0.1kg to more than 30,000kg. In addition to standard quality and environmental accreditations, Bodycote’s HIP facilities hold ASTM, NORSOK, and Nadcap accreditations. www.bodycote.com

Mandelli hosts open house

At the same time as EMO in Milan, Italy, Mandelli Sistemi organized an open house that brought many EMO booth visitors to the company’s premises in nearby Piacenza. Visits began with a presentation of the renovated premises and lean production-oriented facilities, with a detailed description of the machines in production, especially those for aerospace and energy. The Spark 1300 to Spark 2600 models were shown in different assembly phases.

Visitors showed interest in the new spindles produced by Kessler, exclusively for Mandelli Spark HMCs, as well as the Power machining center planned for 2017, with rotary table load up to 30 tons, boring bar equipped with a head-change system, and high-torque mechanical spindles. www.mandelli.com

Silver Boeing Performance Excellence Award to Wetmore Tool & Engineering

The Boeing Company issues the award annually to recognize suppliers who have achieved superior performance. Wetmore Tool and Engineering received the 2014 Boeing Performance Excellence Award, maintaining a Silver composite performance rating for each month of the 12-month performance period, from Oct. 1, 2013, to Sept. 30, 2014.

This year, Boeing recognized 548 suppliers who achieved either a Gold or Silver level Boeing Performance Excellence Award. Wetmore Tool and Engineering is one of 429 suppliers to receive the Silver level of recognition.

“We are honored to receive Boeing’s Supplier Excellence Award,” says Wetmore’s CEO Andrew Pramschufer. “Our employees are the foundation of Wetmore’s success and have created our lean enterprise that focuses on best-in-class quality and delivery performance.” www.hpwetmore.com

Methods Machine Tools partners with 3D Systems

3D Systems has entered into a partner agreement with Methods Machine Tools Inc. to offer 3DS’ full line of professional and production 3D printers and materials.

To spearhead its entrance into the 3D printer market, Methods will add dedicated 3D printing sales, application engineering, and support teams to its seven regional offices throughout the U.S. and will create a state-of-the-art 3D printing showroom with a range of capabilities in each location.

Methods will focus on 3DS’ direct metal printers (DMP) to deliver enhanced solutions to its customer base of more than 30,000 companies. www.3dsystems.com; www.methodsmachine.com