5 Star already has 2 Thermwood machines installed in its Wisbech, UK HQ and manufacturing facility, so the choice of another of the same brand was obvious.  Thermwood, based in Dale, Indiana, was initially selected back in 1999 when 5 Star made its first investment into CNC manufacturing.  Having carried out a comprehensive evaluation of most major brands,  5 Star’s technical and engineering department again chose Thermwood. The principal reasons are Thermwood's excellent pre-sales service, the equipment's simplicity of use, plus recommendation from a number of references.  Back in 1999, Thermwood was one of the first automated machining manufacturers to employ standard PC based control, whilst most other systems utilised bespoke architecture such as Bosch and Fanuc. 

This vacuum uses a large format pump to evacuate air through a grid plenum and spoilboard system, and enables panel hold-down without the need for complex and time-consuming clamps and fixtures.  This is ideal for predominantly flat panel case manufacture, whilst other jig systems can be used alongside the existing universal vacuum.  The three CNC machines differ only by the number and type of cutting tools.  The first is a 5 position ‘Bar Type’ automatic tool-changer. CNC number 2 has Thermwood's latest model which incorporates a ‘Typewriter’ style 5 position auto tool-changer mounted directly on the spindle. In addition, a further 7 tools are situated at the rear of the table, offering a 12 tool selection in total.  The latest machine features an 8 position rotary ‘Turret’ system, where the entire selection of 8 tools are rotated at the head. 

As the polymer is formed the bubbles are trapped in the matrix forming a foam.The constituents can be modified to form foam with many different densities and properties.  Pigments or dyes can be added to one of the components, or injected at the mixing stage so you can have any colour you want.  The pressures involved in this type of moulding are considerably less than injection Moulded inserts.  Therefore, less complex mould tooling can be produced.  Typically, once poured the insert can be removed within minutes (depending on the size of the finished article).
Our team of designers can produce specialist tooling data from Solid Edge v20.  This data can then be sent to the tool-maker to produce the mould tooling.  Usually this is produced from aluminium stock, but can be from resin or even plywood.  Plywwod is by far the cheapest but surface quality is much reduced and the life of the tooling will be relatively short.