Boeing and Thermwood Corporation have employed additive manufacturing technology to produce a large, single-piece tool for the 777X program. The project is demonstrating that additive manufacturing is ready to produce production quality tooling for the aerospace industry.

Thermwood used a Large-Scale Additive Manufacturing (LSAM) machine and newly developed Vertical Layer Print (VLP) 3D printing technology to fabricate the tool as a one-piece print, eliminating the additional cost and schedule required for assembly of multiple 3D printed tooling components. In the joint demonstration program, Thermwood printed and trimmed the 12-foot-long R&D tool at its southern Indiana demonstration lab and delivered it to Boeing in August 2018. Boeing Research & Technology engineer Michael Matlack believes the use of Thermwood’s additive manufacturing technology in this application provided a significant advantage, saving weeks of time and enabling delivery of the tool before traditional tooling could be fabricated.

The tool was printed as a single piece from 20% carbon fiber reinforced ABS using the Vertical Layer Print system. Boeing purchased a Thermwood LSAM machine with the VLP functionality for the Interiors Responsibility Center (IRC) facility in Everett, Washington. The ability to quickly produce large-scale tooling at a quality level suitable for a real-world production environment represents a significant step in moving additive technology from the laboratory to the factory floor.