Airplane model manufacturing is a highly complex and challenging process that involves a wide range of technical and logistical considerations. Designing and building an airplane model requires specialized knowledge and expertise in areas such as aerodynamics, materials science, and manufacturing technology. Additionally, the manufacturing process must comply with a variety of safety and quality standards to ensure the finished product meets the highest standards of safety, reliability, and performance. The supply chain for airplane model manufacturing is also highly complex, involving many different suppliers and vendors that must coordinate their efforts to ensure timely delivery of parts and components. All of these factors make airplane model manufacturing a difficult and complicated process that requires careful planning, execution, and coordination.
Data Collection
Everything starts from data collection. It involves gathering a wide range of information about the real aircraft. This includes technical drawings, photographs, and other documentation related to the design and construction of the aircraft.
3-D Modelling
Once the necessary data has been collected, the next step is to use it to create a 3-D graphic of the aircraft. This is done using specialized 3-D modeling software, which allows our professional designers to create a highly accurate representation of the aircraft.
Mold Building and Casting
The 3-D digital model will be optimized and divided into several parts for mold-making and casting. A negative mold is created using CNC machining, which involves cutting the mold out of a block of material using a computer-controlled cutting tool. The next step is to create the positive mold by pouring silicone or urethane into the negative mold and allowing it to cure.
Injection
Injection is a manufacturing process used to create complex shapes and designs of plastic or metal parts. It involves injecting molten material into the mold under high pressure, which is then cooled and solidified to form the finished part.
Line Drawing
The designer will carefully observe the livery details of the real aircraft and redraw them on the blank 2-D line drawing templates. The process involves a lot of data collection and the designer’s professional judgment. Once the image has been prepared, it is printed onto a transfer pad using a specialized printing technique.
Spray Painting
The coloring process starts with spray painting. It begins with thorough cleaning and masking of the model’s surface. The model is then placed in a spray booth, where a painter uses a spray gun to apply a thin layer of paint. After the paint dries, the model is inspected for defects, and touch-ups are made as necessary. The process is repeated until the desired level of coverage and finish is achieved.
Tampo Printing
Tampo printing, also known as pad printing, is a popular printing method used to transfer a 2-D image onto a 3-D surface using a transfer pad which is made of a soft, flexible material. This process can be repeated multiple times, allowing for the creation of highly detailed and accurate prints. It can take up to dozens of tampo printing steps to complete just one single aircraft model.
Coating
Coating with varnish involves applying a layer of clear liquid coating onto the surface of the printed parts to protect it from wear and tear and to enhance its appearance with a glossy, high-quality finish. After the varnish has been applied, it is left to dry and cure for several hours or even days. A hard, transparent layer will be formed on the surface to protect the aircraft from scratches, moisture, and other types of damage.
Assembling
Assembling is the process of joining the components together to create a complete aircraft model. After gathering all components, the workers will clean and check them to ensure that they fit together correctly. The components are then joined together correctly with specially fomulated super glue.
Quality Check
Once the assembly process is complete, the finished model is inspected to ensure that it meets the required specifications and quality standards. Any necessary adjustments or repairs are made before the model is packaged and shipped. The strict QC specialists will visually inspect the models for any defects, such as scratches, dents, or discoloration. It is a critical component of the manufacturing process, as it ensures that the products are safe, functional, and meet the needs of the customer.
Packing
Packing is the final step in the manufacturing process and involves preparing the finished products for shipment to the customer. The goal of packing is to ensure that the products arrive at their destination safely and in good condition. Suitable protection material including foam, plastic capsule or shrink wrap will be used, according to the size, weight, and fragility of the model. The protected model is then packed in a perfectly sized and exquisitely designed box.
Interested in having Lee Hing handle all of these for you? Please do not hesitate to contact us for further information on our services.