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Company Overview
Thermwood Corporation (Dale, Indiana) is a US CNC machine tool manufacturer that developed the LSAM (Large Scale Additive Manufacturing) system — the dominant gantry-based LFAM platform for thermoplastic composite tooling in the aerospace and defense market. Thermwood is privately held and has been making CNC routers since 1969; LSAM was introduced around 2016 as a natural extension of their large-format machining expertise.
The LSAM’s competitive position rests on a combined print-then-trim workflow: the same gantry machine that 3D prints large composite parts can flip to CNC trimming mode, producing finished near-net-shape parts without moving to a separate machining center. This near-net workflow is critical for autoclave cure tooling, where dimensional accuracy determines part quality.
LSAM System Family
LSAM (Full Combined Systems)
Dual-gantry machines that both print (additive) and trim (subtractive) on the same platform. Available in table sizes ranging from 10×5 ft to 40+ ft lengths. Capable of printing parts up to ~10 ft tall.
- Print head: High-temperature pellet extruder; up to 450°C processing temperature
- Control: Ultra 6 CNC control (same platform across all LSAM variants)
- Materials: CF-ABS, CF-Nylon, CF-PEI (ULTEM), CF-PEEK, CF-PEKK, and virtually any composite thermoplastic pellet
- Deposition rate: ~100–150 kg/hr depending on material and head configuration
- Applications: Autoclave cure tooling, lay-up molds, patterns, structural parts
LSAM AP510 (Additive Printer Only)
Lower-cost print-only variant introduced to broaden market access. Fixed gantry, moving table design.
- Table sizes: 5×5 ft and 5×10 ft
- Max part height: ~4 ft
- Print head: Same as full LSAM; same Ultra 6 control
- Target market: R&D departments, job shops, lower-volume tooling production
- Notable demo: JEC World 2026 live print of matched drone mold pairs from CF-polycarbonate
Key Customers & Programs
| Customer | Program | Notes |
|---|---|---|
| Boeing | 777X cure tooling | First LFAM-produced autoclave-capable production tool for a commercial aircraft program; validated LFAM for production-quality aerospace tooling |
| Boeing / AFRL | Low Cost Responsive Tooling (LCRT) | Air Force Research Laboratory program evaluating LFAM for low-cost autoclave composite tooling for defense aircraft; Boeing as prime, Thermwood as machine supplier |
| Bell Textron | Main rotor blade mold | 18.5-foot helicopter blade mold; believed to be the largest LFAM autoclave-capable tool at time of production |
| General Atomics | CNC trim tool | ~$50K cost savings vs. traditional machining |
Materials Ecosystem
Thermwood collaborates with material suppliers to qualify new pellet feedstocks for LSAM. JEC World 2026 demo used CF-polycarbonate from Airtech, SABIC, and Techmer PM simultaneously — demonstrating multi-supplier material qualification. The LSAM system can process virtually any thermoplastic composite pellet at temperatures up to 450°C.
Competitive Position
Thermwood’s main competition in gantry-based LFAM is Ingersoll Machine Tools (MasterPrint). Thermwood differentiates on:
- Combined print+trim in one machine (Ingersoll requires separate machining)
- Extensive aerospace customer validation (Boeing, AFRL programs)
- US-manufactured system (important for defense procurement)
- Lower entry price via LSAM AP510