Case study of power equipment model production: full process of transformer model production
1、 Design and Material Preparation
The design plan reproduces the real transformer at a scale of 1:20, and divides the modules according to the original factory design drawings: iron core, coil, shell, and auxiliary components (radiator, terminals, etc.). Use CAD to draw 3D drawings to ensure accurate matching of dimensions for each component.
Material selection
Main structure: The outer shell is made of ABS plastic board, and the acrylic board serves as a transparent observation window, balancing strength and display requirements.
Core components: brass wire wound analog coil, detachable iron core made of stacked iron sheets for easy display of magnetic circuit.
Auxiliary components: Aluminum alloy processed terminals and heat sinks to enhance the metallic texture.
2、 Production process
Component processing
Coil winding: The brass wire is precisely wound according to the designed number of turns and fixed on an insulating bracket to distinguish the color of the primary/secondary winding.
Iron core assembly: The iron sheets are laser cut and stacked, bonded with epoxy resin, and the edges are polished to avoid burrs.
Shell Forming: The ABS board is CNC engraved with a curved surface, and the acrylic observation window is seamlessly bonded with UV glue.
The dynamic system is integrated with a micro LED strip embedded internally, simulating the current path through a transparent shell; The coil is connected to a magnetic spring switch to switch the light according to the power on state.
3、 Post processing and coloring
surface treatment
Polish the joints with 600 grit sandpaper, fill the defects with atomic ash, and then polish with 1200 grit sandpaper to achieve a mirror effect.
Spray gray primer to enhance adhesion, especially for PETG material components.
Industrial style coating
Main color tone: Spray gun sprayed with dark gray metallic paint (such as Tamiya TS-77), simulating transformer casing.
Detail differentiation: The coil retains copper color or is sprayed with matte black, the iron core is coated with imitation rust color, and the terminals are painted with silver enamel paint.
Identification production: Water stickers are printed with voltage levels and logos, and covered with protective paint to prevent wear and tear.
4、 Restoration Enhancement Techniques
Detail enhancement
Use etching chips to create heat sink textures, and simulate cable joints with 0.1mm copper wire.
Aging treatment: Staining solution+powder color simulation oil stains, dry scanning highlights metal wear.
Dynamically verify the synchronization between lighting and mechanical actions, adjust LED brightness to make the current path clear and visible, and ultimately achieve a restoration rate of over 90%.
5、 Case Summary
This case balances display and operability through modular design, multi material composite technology, and industrial grade coating. The key point is:
Material adaptation: ABS and metal combination balance lightweight and realism;
Interdisciplinary craftsmanship: 3D printing of complex components+manual refinement of details;
Dynamic demonstration: Enhancing interactive teaching of electronic control system
