Manufacturer of energy storage cabinet model

Case study on the production of proportion model for energy storage cabinet

The aim of this project is to create a 1:10 scale energy storage cabinet display model, which requires a highly realistic appearance of the product, rich details, and realistic texture, with a final restoration degree of over 90%. The entire production process does not involve internal electrical structures and focuses entirely on the simulation replication of the appearance.

1、 Design and Material Preparation

Firstly, the project team obtained the complete set of exterior design drawings and high-definition photos of the original product. Perform precise scaling calculations based on proportions, and convert all exterior dimensions, door gaps, ventilation hole layouts, signage positions, and other details into machining drawings for the model.

The selection of core materials is based on the principles of "texture simulation" and "ease of processing":

Main structural materials: Acrylic board and ABS engineering plastic board are selected. Acrylic board is used to make large-area flat surfaces such as cabinet side panels and top covers. Its high transparency and easy polishing properties are suitable for post production observation windows; ABS board is used to make door panels, frames, and various small structural components due to its excellent toughness and easy bonding properties.

Detail accessories: including ABS round and square rods of different diameters for simulating pipes and cables, metal etching sheets for making extremely fine ventilation grilles and brand logos, high-precision 3D printing resin for manufacturing complex curved parts that cannot be achieved through sheet metal processing, such as fan covers, special handles, etc.

2、 Core manufacturing process

Precision cutting and forming: All cutting of the main board is completed by laser cutting. This ensures absolute precision in all panel dimensions, smooth and burr free edges and corners, and the ability to accurately cut all ventilation louver holes, door gaps, and installation holes in one go, with efficiency and accuracy far exceeding manual labor. For parts that need to be bent, such as certain sheet metal structures, a hot bending machine is used to heat and shape the ABS board to obtain neat and accurately angled folds.

Detail carving and addition: All text, warning signs, and parameter labels (with simulated content) on the surface of the model are directly printed in the corresponding positions using high-precision UV flatbed printing technology, with clarity comparable to real printed materials. For signs with a textured feel, shallow carving techniques are used, followed by ink filling to reproduce the true tactile sensation.

Assembly and polishing: Use specialized model glue and instant glue for bonding to ensure a firm and precise joint, avoiding glue overflow and affecting aesthetics. After all components are assembled, it enters the crucial polishing stage. Using sandpaper of different types from coarse to fine, polish all joint seams, cutting ports, and surface defects one by one until the entire surface of the model feels smooth and flat, and all joints are almost imperceptible to the naked eye, laying a perfect foundation for subsequent coloring.

3、 Post processing and coloring

This is the most crucial step in endowing the model with a "soul" and achieving high fidelity.

Primer treatment: Apply a gray model specific primer as a whole. This is not only to enhance the adhesion of the topcoat, but also to unify the colors of all parts made of different materials, and to expose extremely subtle surface defects again for final repair, while forming a uniform frosted texture substrate.

Layered spraying topcoat: Strictly mix the paint according to the original product color code, and use a spray pen for multi-layer thin spraying. Firstly, spray the main base color. After it is completely dry, use masking tape to accurately cover different color areas, and then spray the second and third colors. This method ensures clear and sharp color boundaries, just like real sheet metal spray painting.

Aging and texture creation: To achieve the texture of real devices, it is not simply spraying a single color block. We will also use stain washing technology to infiltrate a small amount of dark oil-based paint into concave lines, rivets, and gaps, deepening shadows and highlighting a three-dimensional effect; Perform a slight dry sweep on frequently touched door handles, corners, etc., and use light colored paint to simulate the natural wear effect. Ventilation grilles, exhaust outlets, and other locations will be filtered with diluted black paint to simulate deep shadows and slight dust accumulation inside.

Final assembly and protection: After all paint surfaces are thoroughly dried, the final assembly is carried out, and independently made glass observation windows (transparent acrylic), 3D printed fine handles, metal etched logos, etc. are installed. Finally, a layer of matte protective paint is sprayed as a whole to unify the glossiness of all components (industrial equipment often has a matte texture), and to protect the delicate paint surface from scratches and oxidation.

Through a series of rigorous processes and material selection, the final energy storage cabinet model is not only precise in terms of external dimensions, but also extremely close to the real product in terms of color, texture, details, and even visual weight. It has successfully achieved the production goal of more than 90% restoration, becoming a high-quality model with great display value