Thermwood LSAM Print Only
Key Specifications
Print Volume (X × Y × Z)
Deposition Rate
Print Head Type
Materials
Layer Height Range
Platen Heating
Overview
The Thermwood LSAM Print Only system is the dedicated additive manufacturing configuration of Thermwood's Large Scale Additive Manufacturing platform — a large-format, high-rate polymer extrusion system optimized for producing near-net-shape aerospace tooling, composite layup mandrels, jigs, and large structural preforms at throughput rates not achievable by any other commercially available additive technology. Unlike the LSAM-MT hybrid system, the Print Only configuration omits the integrated 5-axis trim gantry, allowing the platform to focus exclusively on high-volume, high-speed material deposition. Parts produced on the Print Only system are subsequently transferred to a separate CNC router or machining center for surface finishing and dimensional trimming.
Thermwood's Print Only configuration is the platform of choice for facilities that already operate large CNC routers or 5-axis machining centers and need to add additive capability without duplicating subtractive infrastructure. By separating the print and trim operations, shops can run the LSAM continuously on additive production while the CNC machines handle trimming, achieving higher overall throughput than a single hybrid system permits. The print head — a high-output screw-driven pellet extruder — can deposit material at rates exceeding 100 kg per hour using carbon fiber-reinforced thermoplastic pellets, making it capable of building large aerospace tooling structures in hours rather than the days required by filament-based or photopolymer additive systems.
The LSAM Print Only is particularly valued in aerospace tooling programs where the printed structure is used as a near-net-shape core that receives a secondary tool face — either a sprayed or laminated composite skin — rather than being machined to a tight dimensional tolerance. Wingstringer layup tools, fuselage frame mandrels, and large oven-cure molds are typical applications. The controlled thermal environment during printing, combined with Thermwood's validated slicing and process parameters for CF-ABS and CF-PESU, produces parts with predictable distortion and reliable CTE matching to aluminum tooling standards.
The system is controlled by Thermwood's Q-Core platform with an additive-specific interface for managing extrusion temperature, layer strategy, bead geometry, and in-process monitoring. Remote monitoring and process data logging support production quality documentation requirements for aerospace customers operating under AS9100 quality management systems.
Full Specifications
| Parameter | Value |
|---|---|
| Print Volume (X × Y × Z) | Up to 10,000 × 3,000 × 1,500 mm (configurable) |
| Deposition Rate | Up to 100+ kg/hr |
| Print Head Type | Screw-driven pellet extruder |
| Materials | CF-ABS, CF-PESU, CF-PEI (Ultem), PPS, PEEK blends |
| Layer Height Range | 3–10 mm (bead scale) |
| Platen Heating | Yes — for thermal management and warp control |
| Control | Thermwood Q-Core (additive configuration) |
| Axes | 3-axis gantry (X/Y/Z) |
| Connectivity | Ethernet, remote monitoring capability |
| Footprint | Custom to print volume — typically 8–25 m length |
| Manufacturer | Kentwood |
Specifications sourced from machinio.com — verified 2026-03-28
Strengths & Limitations
Strengths
- Highest-rate polymer deposition available commercially — 100+ kg/hr enables large aerospace tooling in hours, not days
- Lower acquisition cost than LSAM-MT hybrid for shops that already own CNC routers for subtractive trimming
- Continuous additive production is possible while CNC routers independently handle trimming of completed prints
- Validated material and process parameters for CF-ABS and CF-PESU reduce qualification effort for new aerospace tooling programs
- Thermwood's American manufacture and service base provides responsive support for production aerospace environments
Limitations
- No integrated trimming — all finished surface work requires transfer to a separate CNC machine, adding handling risk and datum re-establishment
- Bead-scale deposition limits geometric resolution — fine features and tight surface tolerances require extensive post-processing
- Very high energy and facility infrastructure requirements including heavy three-phase power and controlled thermal environment
Best For
Frequently Asked Questions
01
The LSAM Print Only includes only the additive printing gantry and has no integrated CNC trimming capability. All subtractive work must be done on a separate machine. The LSAM-MT adds a second 5-axis trim gantry on the same rail system, enabling in-process and post-print machining without transferring the part. The Print Only is less expensive and better suited for shops with existing CNC infrastructure; the LSAM-MT is better for facilities that want a self-contained solution.
02
Near-net-shape accuracy from the LSAM Print Only is typically ±1–3 mm depending on part geometry, material, and print parameters. This is sufficient for most tooling applications where the critical surfaces will be trimmed or laminated afterward. Thermwood's process engineering team provides guidelines for designing print strategies that minimize distortion and achieve the tightest possible near-net accuracy.
03
The LSAM Print Only is designed for sustained production operation. The pellet hopper can be loaded with bulk material to support multi-hour or overnight print runs. Remote monitoring via the Q-Core system allows operators to track extrusion temperature, layer progress, and alarm conditions without continuous on-machine attendance. Preventive maintenance intervals are defined in Thermwood's service documentation.
04
Thermwood provides a customized slicing and toolpath generation software package integrated with the Q-Core control. The software accepts standard STL or STEP input, generates print toolpaths with user-defined bead geometry and layer strategies, and outputs G-code directly for the LSAM. Thermwood's applications engineers assist with process setup for new materials and part geometries during system commissioning.
05
Yes. Thermwood LSAM technology has been evaluated and deployed by Boeing, NASA Marshall Space Flight Center, the U.S. Army, and multiple Tier 1 aerospace suppliers. Applications include composite layup tools, autoclave-compatible mandrels (in CF-PESU and CF-PEI), trim fixtures, and large structural test fixtures. Boeing and NASA have published results from LSAM tooling validation programs in public technical papers.
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