High-speed rail model manufacturing company

Project Background

This case study uses the Chinese Standard EMU Fuxing as a prototype to create a display-grade model at a 1:87 scale, aiming to achieve 90% appearance fidelity. The model is primarily intended for display in railway cultural exhibition halls. The model measures approximately 52 cm in length and features a modular, modularized design. The main materials used are ABS engineering plastic and alloy die-cast components.

Core Manufacturing Processes

1. Precision Mold Development

3D Scanning Modeling

A white light scanner was used to collect point cloud data from the actual vehicle. Geomagic Wrap software was employed to repair surface defects, ensuring that the error in the streamlined curves of the front end was ≤0.3mm.

Steel Mold Carving

Japanese Mori Seiki five-axis CNC machining centers are used to carve the molds, with a focus on complex components such as bogies and pantographs. The mold cavity surfaces are mirror-polished to reduce injection molding flow marks.

2. Component Production

Body Injection Molding

German Bayer TG-43 ABS pellets are used, with injection molding temperatures controlled at 230±5°C.

Each mold is equipped with 12 hidden vent holes to prevent bubbles in thin-walled areas such as window frames.  

Metal Parts Die Casting  

Load-bearing components such as bogies and coupling hooks are die-cast using zinc alloy (ZA-8).

Internal porosity is inspected via X-ray testing, with scrap rate controlled below 3%.

Manual Finishing Stage

Seam Treatment

The roof spoiler is bonded using Tamiya White Cap adhesive, then sanded with 800-grit waterproof sandpaper after 24 hours of curing.

Inject a small amount of molybdenum disulfide grease into the wheel axle area to ensure smooth rotation

Surface pre-treatment

Apply Gunze 1000 Gray Water Putty to the entire vehicle to expose defects such as 3D printing patterns

Use atomized putty to fill the parting lines, repeating the scraping-grinding cycle until the surface feels smooth

Use a 0.2mm nozzle spray gun to apply the standard colors of the Fuxing bullet train (Pantone color chart: 19-1664TPX Red + 18-4148TPX White)