3D printing additive manufacturing future manufacturing industry is beginning to take shape

As 3D printing and additive manufacturing technologies gain more traction in the manufacturing industry, an increasing number of traditional machining equipment manufacturers are integrating additive capabilities into their material-removal systems. This shift is enabling them to develop more advanced hybrid manufacturing solutions. For instance, Thermwood, Inc., a U.S.-based company with over 50 years of experience in CNC machining, is now exploring the use of both additive and subtractive methods on a single machine to produce large-scale graphite-reinforced composite thermoplastic parts. To achieve this, Thermwood modified its Thermwood Model 77 by adding a second gantry and mounting a large extruder capable of heating and melting graphite. The company also partnered with Kuhne, a renowned U.S. manufacturer of extrusion systems, to develop custom solutions for plastics, rubber, and silicones. This collaboration has led to the creation of a specialized extruder system that seamlessly integrates with existing CNC machines and offers full control over the extrusion process. The original Thermwood Model 77 is a massive, enclosed gantry machine that can be expanded up to 60 feet in size. The new extruder system developed by Kuhne is fully compatible with this platform and allows for 3D printing on any plane—whether horizontal, vertical, or at any angle in between. Thermwood believes this flexibility will play a crucial role in enabling the production of more complex and intricate structures in the future. Once the 3D-printed portion of the part reaches a near-final shape (known as the “near shape process”), the Thermwood Model 77 performs five-axis machining to achieve the final form. These parts can be as large as 10 x 10 x 5 feet. The extruder features 20 horsepower and a nozzle diameter of 1.75 inches, capable of processing up to 100 pounds of material per hour. Despite its substantial size, the custom-built system significantly enhances production efficiency. This project is still in development, and Thermwood has not yet revealed when it will be commercially available. However, the company sees significant potential in additive manufacturing and views it as a key component of the future of manufacturing. With its strong background in traditional machining, Thermwood feels well-positioned to lead in this emerging field.

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