Automobile chassis model manufacturing factory

Industrialised Manufacturing Process for the Demonstration Model of the Chassis Structure of New Energy Vehicles

1. Main Frame Forming Process

Load-bearing Structure: A modular skeleton is constructed using aluminium alloy extruded profiles. All connection points are marked with laser-engraved positioning marks to ensure that the installation position error of each assembly is ≤0.3mm.

Battery Compartment Manufacturing: The surface texture of the explosion-proof valve on the actual battery pack is replicated using a silicone mould. Magnetic, removable shelves are installed inside to display the arrangement of the battery cells.

Suspension System: The double A-arm structure is formed using 304 stainless steel wire cutting, with miniature bearings embedded at the ball joint to achieve realistic motion travel.

2. Key Component Detail Processing

Motor Assembly: The housing is precision cast using the lost-wax method, with the stator windings hand-woven using silver-plated copper wire, and the rotor permanent magnets undergo demagnetisation treatment.

Transmission system: The differential housing features a transparent design, with the internal planetary gearset distinguished by anodised colour coding.

Piping layout: High-voltage wiring harnesses are made from flexible TPU material via extrusion moulding, with the original vehicle wiring labels laser-engraved on the surface.

III. Surface Treatment System

Pre-treatment stage:

Aluminium alloy components undergo chromic acid passivation treatment.

Plastic parts undergo plasma activation

Copper components coated with anti-discolouration coating

Painting scheme:

High-pressure system: Warning orange (RAL2008) with matte clear coat

Structural components: Electrocoat grey (RAL7035) with brushed finish

Moving parts: PVD coating simulating metal wear marks

Logo restoration:

Safety warning labels using screen printing process

Part numbers using UV-curable ink

4. Dynamic display functionality integration

Brushless motor embedded in the drive motor to simulate operation

Battery pack with LED light strips to display charging/discharging status