Small batch customized excavator model production case
1、 Customization requirements and preliminary preparation
When customizing excavator models in small batches, it is necessary to first have in-depth communication with the customer to clarify core requirements such as proportions (such as 1:20, 1:30), functions (static display/dynamic demonstration), and details (such as whether to restore the hydraulic system and the interior of the cab). Subsequently, based on customer requirements, the excavator structure was disassembled and the model was divided into core components such as chassis, boom, boom, bucket, cab, tracks, etc. A detailed production process and material list were developed.
2、 Manufacturing process of core components
1. Vehicle body and structural components
Chassis and tracks: Made of ABS engineering plastic sheet, the chassis contour is precisely cut through laser cutting; The tracks are injection molded with PVC material to ensure that the size and spacing of each track section are consistent with the actual excavator.
Boom, arm, and bucket: The boom and arm are made into master molds using 3D printing technology, and the curved lines are manually polished after printing to ensure smooth structure; The bucket is injection molded with metal powder, and after molding, it is polished twice to give the edge of the bucket a metallic luster, simulating the wear resistance of a real bucket.
2. Hydraulic system and details
Hydraulic pipeline: Wrap the simulated hydraulic pipeline with thin copper wire, leaving a 0.2mm gap during winding to ensure flexible rotation during subsequent assembly; The hydraulic cylinder is lined with stainless steel tubing and covered with heat shrink tubing to restore the texture of the real hydraulic cylinder.
Cab and interior: The cab is made of PVC board cut and molded, and the internal seats are restored to their true seat texture using UV printing technology; The car window is made of 0.8mm thick acrylic sheet, which is precisely cut by a CNC engraving machine, and the edges are treated with a flame polishing machine to ensure transparency.
3、 Assembly and detail optimization
Component assembly welding: First assemble the chassis, reserve the installation position for the car window, and manually adjust the curvature to ensure that the car window frame fits perfectly with the side wall; The roof and side walls are connected using a mortise and tenon structure. Special adhesive is applied first, and then micro fixtures are used to fix them for 24 hours to ensure the connection strength.
Front end and boom: The front end is processed by dividing the 3D printed master mold into pieces. After each piece is adjusted and shaped, it is fixed with a positioning fixture. The deformation is prevented through the "point fixing welding reinforcement" process. Finally, the process beam is removed and the weld seam is polished to make the front end line smooth and natural.
Detail processing: The car number and logo on the body are printed using transfer printing technology, with font size controlled at around 1.5mm, which is clear and recognizable; The spring system of the bogie is manually wrapped with stainless steel wire, with a diameter of only 0.3mm, simulating the real shock absorption effect.
4、 Painting and post inspection
Painting process: The painting workshop adopts a dust-free spraying process, first spraying white primer, and then spraying the engineering colors specified by the customer (such as yellow and blue). Through multiple adjustments of the color paste ratio, the color is ensured to be consistent with the original vehicle; The streamlined ribbon on the front of the car adopts screen printing technology to ensure clear edges without smudging.
Detail refinement: Before installing the car window glass, stick a black sealing strip on the inside of the window frame to simulate the sealing structure of a real car window; The seat is cut from PVC board and the surface is restored with UV printing technology to restore the seat texture.
Inspection and delivery: After the final assembly is completed, a comprehensive inspection is carried out to check whether the vehicle body is stable, whether each component rotates flexibly, and whether there are defects in the coating; The dynamic model will also undergo power on testing to ensure that the LED lights (headlights, interior lighting) are on normally and the power system runs smoothly. The qualified models shall be put into the packing box with foam lining to ensure safe transportation.
