CutLayer Introduction

Описание: An all new large format additive process. Large format additive using material you can't print.

More info: https://bit.ly/44SBKVP

Called “CutLayer ”, this new additive approach produces large format, near-net-shape parts at incredibly low cost, using a lower cost additive machine. Unlike large format additive printers (like Thermwood’s LSAM), the new process makes large parts from a variety of materials that can’t be printed.
CutLayer parts are similar to large additively printed parts, in that they are essentially hollow structures made in layers. However, instead of printing the layers, they are instead cut from thick sheets.

To make this work, each layer is separated into two or more segments, which can then be rather efficiently nested on sheets of about any material that can be machined. Once cut out, the layer segments are re-connected using precision puzzle joints, machined into the segment ends. Dowel alignment holes, between layers, assure alignment, making assembly accurate and easy.
Overall, the process, both cut and assemble, takes (at most), the same amount of time and labor as needed to additively print the same part. With some material, it can be faster, sometimes a lot faster, plus, material cost can be almost shockingly low.
One interesting use of this process is to make the part from a porous material, machine it to final size and shape and then add a penetrating thermoset resin, such as epoxy, which soaks in and hardens, producing a large thermoset composite part. Thermwood used this process to produce a 12-foot-long aerospace tool for the incredibly low material cost of $2,000, in less time than it took to additively print the same part.
CutLayer can also make parts from metal as long as the metal can be CNC routed. To demonstrate this, Thermwood made a large aerospace trim fixture using aluminum. Its walls are only a bit over an inch thick, meaning it used less material than about any other way of making it.
Although the idea is simple, until now, doing it has been all but impossible.
Creating nested CNC programs to machine hundreds upon hundreds of individual layer-segments, each with a multitude of machining requirements, that must all precisely mesh together, is a truly monumental programming task. And all, just to make a single part.
Totally impractical with traditional programming. It just doesn’t make sense. Programming cost would overwhelm any possible savings.
00:00 Introduction
00:31 What is it?
00:50 Aerospace Production Layup Tool made with CutLayer
01:45 Aerospace Production Layup Tool 3D Printed Comparision
03:27 Aerospace Trim Fixture made from Aluminum with CutLayer
05:56 Thermoset Additive Produces Low Cost Parts
06:16 Why Hasn't Anyone Done This Before?
07:53 Machine Intelligence
10:08 Telling the Machine What You Want
10:41 CutLayer Does the Hard Stuff Automatically
11:17 CutLayer Makes Sense
12:00 What to Do with the Parts?
12:44 How to Attach Layers
13:26 Thoughts on Materials
13:51 CutLayer Summary
14:50 Outro