As 3D printing and additive manufacturing technologies gain more traction in the manufacturing industry, an increasing number of traditional machining companies are integrating additive capabilities into their subtractive equipment, enabling them to offer advanced hybrid manufacturing solutions. For instance, Thermwood, Inc., a U.S.-based CNC machining company with over 50 years of experience, is now exploring the combination of both additive and subtractive manufacturing on a single machine to produce large-scale graphite-reinforced composite thermoplastic parts.
To achieve this, Thermwood added a second gantry to its Thermwood Model 77, equipping it with a large extruder capable of heating and melting graphite. The company also partnered with Kuhne, a well-known manufacturer of extruders in the engineering sector, to develop custom systems for plastics, rubber, and silicones.
The original Thermwood Model 77 is a large, enclosed gantry machine that can be expanded up to 60 feet. Kuhne designed a custom extruder system compatible with existing CNC machines, allowing full control and management of the extrusion process.
This new system can perform 3D printing on any plane, from strictly horizontal to vertical 90-degree angles, and everything in between. Thermwood believes this flexibility will be key to creating more complex structures in the future.
Once the 3D-printed part reaches a near-final shape—known as the "near shape process"—the Thermwood Model 77 then uses five-axis machining to achieve the final desired form. These parts can be as large as 10 x 10 x 5 feet. The extruder has 20 horsepower and a nozzle diameter of 1.75 inches, capable of processing up to 100 pounds of material per hour. Despite its heavy appearance, the custom-built machine significantly speeds up production.
Although this project is still under development, Thermwood's management hasn't revealed an exact timeline for commercial availability. However, they see great potential in additive manufacturing, viewing it as a crucial component of the future of manufacturing. With its strong background in subtractive manufacturing, Thermwood believes it is well-positioned to lead in this emerging field.
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