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Thermwood (Dale, Ind., U.S.) is demonstrating the capabilities behind its large-scale additive manufacturing (LSAM) technology through live 3D printing and interactive demonstrations.

Each day at JEC World 2025, the company is live-printing a double-sided RTM mold for an underwater tidal turbine blade. The mold pairs will be printed on an LSAM AP 510 additive printer using carbon fiber-reinforced materials, with a different material supplier featured each day (SABIC and Techmer PM). This printer features a single-fixed gantry, 5' × 10' moving table, 4' maximum print height and a maximum print temperature of 450°F (232°C). Once printed, these RTM mold pairs will be shipped from the event, machined and subsequently used to produce actual tidal turbine blades.

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In addition, Thermwood is presenting an interactive demonstration twice a day that enables attendees to see firsthand how LSAM technology prints and finishes large-scale thermoplastic parts with precision, speed and efficiency. The company is highlighting the wide range of material options and design flexibility available, as well as some of the patented features that Thermwood says set its LSAM systems apart. Topics covered include collaborative projects, ongoing research initiatives and illuminating case studies that help accelerate advancements in comprehensive knowledge and future innovation within the field.

Eduardo Barocio, director of Composites Additive Manufacturing and Simulation (CAMS) Consortium at Purdue University’s Composite Manufacturing & Simulation Center, is also on hand to demonstrate their Additive3D software, a tool that simulates workflow and predicts the printing and as-manufactured performance of parts produced through extrusion deposition AM.

Participants have the opportunity to pose questions to industry experts and gain valuable insights into how LSAM can elevate and optimize the production process. This live demonstration aims to bridge the gap between theory and practical application and help attendees understand the full potential of LSAM and how it can help enhance productivity and innovation. 

Thermwood’s LSAM Additive Printers systems are single-gantry, moving table configurations and are available in two table sizes, 5' × 5' and 5' × 10'. The latter is available in two configurations — 5' wide with 10' of front-to-back motion and 10' wide with 5' of front-to-back motion. Choice of configuration depends on several factors, fitting it existing factory floor space is one factor.

The highly rigid tab and slot, structural steel gantry also incorporates a fume extraction system that pulls print fumes through specially designed activated charcoal filters to remove them and “sweeten” the air.

LSAM Additive Printers use the exact same print head mechanism as all the others, including Thermwood’s largest LSAM systems. They also use the same Ultra 6 control with its print features and capability. The systems come standard with a single hopper polymer dryer for applications that don’t change print material very often. For installations that print a wider variety of materials, a dual hopper dryer is available as an option.

An enclosure that surrounds the machine is also available. The machine with the full enclosure can also be built to meet European CE standards.

Visit Thermwood at JEC World’s Live Demo Area and Booth P52 in Hall 6.