Project Background
This case study addresses the needs of clients in the new energy industry by creating a 1:20 scale container-type liquid-cooled energy storage system display model. The model must accurately depict the equipment's exterior features, piping layout, and cooling structure, with a fidelity of over 90%.
Core Manufacturing Processes
1. Main Structure Formation
Laser-cut acrylic panels are used to construct the container frame, with side panel thickness precisely controlled to 2mm to replicate the texture of real steel plates.
Internal supports are 3D-printed using ABS resin, with optimised support structures ensuring forming accuracy for thin-walled components (minimum 0.8mm).
The top-mounted cooling fan assembly adopts a modular design, with blades injection-moulded separately before assembly to ensure flexibility of moving parts.
2. Liquid Cooling System Replication
Copper capillary tubes simulate cooling pipes, manually bent into shape after annealing treatment.
The cooling storage device housing is made of transparent PC material, filled with blue gradient resin to simulate the state of coolant.
The pump valve assembly is produced using micro-casting technology, with a matte sandblasted finish on the surface.
3. Electrical system details
The battery module array uses CNC-engraved bakelite circuit boards with laser-etched circuit pattern stickers.
High-voltage terminals are assembled using silver-plated copper columns and silicone wires.
The distribution cabinet door is designed as a magnetic, openable structure, with internal wiring marked using coloured heat-shrink tubing.
Material selection scheme
Exterior components: ASA engineering plastic
Transparent components: UV-resistant polycarbonate
Metal-textured components: CNC-machined aluminium-magnesium alloy parts
Decorative film: 3M series reflective film
Surface treatment process
1. Pre-treatment stage
Ultrasonic cleaning of all components to remove release agent
800-grit water sanding of joint surfaces
Application of PP primer to enhance adhesion
2. Coating application
The container body uses electrostatic spraying technology, first applying a sand texture primer followed by a topcoat
Warning signs use screen printing technology
Rust effects are achieved through enamel paint staining
3. Final processing
The entire vehicle is coated with a matte protective paint
Brown staining solution is applied to the seams to enhance three-dimensionality
The control panel is covered with a 0.1mm acrylic protective film
