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As 3D printing and additive manufacturing technologies continue to gain traction in the manufacturing sector, an increasing number of traditional machining companies are integrating additive capabilities into their subtractive equipment. This has led to the rise of hybrid manufacturing systems that combine both methods for greater flexibility and efficiency. For instance, Thermwood, Inc., a U.S.-based company with over 50 years of experience in CNC machining, is now exploring ways to merge additive and subtractive processes on a single machine. Their goal is to produce large-scale graphite-reinforced composite thermoplastic parts with enhanced precision and complexity.
To achieve this, Thermwood modified its Thermwood Model 77 by adding a second gantry and installing a large extruder capable of heating and melting graphite. The company also partnered with Kuhne, a renowned manufacturer of extrusion systems, to develop custom solutions for plastics, rubber, and silicones. This collaboration ensured seamless integration between the extruder and existing CNC machinery, allowing for precise control and coordination.
The original Thermwood Model 77 is a massive, enclosed gantry machine that can be expanded up to 60 feet in size. Kuhne designed a specialized extruder system that works in harmony with the CNC setup, enabling the machine to perform 3D printing on any plane—whether horizontal, vertical, or at any angle in between. Thermwood believes this capability will be crucial for creating more complex and intricate structures in the future.
Once the 3D-printed part reaches a near-final shape, the Thermwood Model 77 then performs five-axis machining to refine it into the desired 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 heavy appearance, the custom-built system significantly speeds up production, making it ideal for high-volume applications.
This project is still in development, and Thermwood’s management hasn’t announced a specific release date for a commercial version. However, they are confident that additive manufacturing will become a vital part of the future of manufacturing. With their strong background in subtractive manufacturing, Thermwood sees itself well-positioned to lead the way in this emerging field.
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