Showcase Manufacture of Concept Car Model

You will find the personnel and time requirements for the manufacture of the concept car below:
Day

Persons

Time*

Preparatory works: CAD/CAM

48**

Gluing the blocks

Milling the styrofoam core

Combining core and blocks

0.1

Rough-cutting the styrofoam model

6.5

Finish-cutting the styrofoam model

Extruding the car model (by machine and by hand)

Curing of the paste (PU: approx. 6-12 hours, epoxy: approx. 48-72 hours)***

Rough-cutting the extruded model

10

5/6

Finish-cutting the extruded model

20

Milling of the styrofoam tyres incl. styrofoam counter tyre holder

Extruding the tyres with PU paste

Curing of the paste

--

12

Rough-cutting 4 tyres

Finish-cutting 4 tyres

0
1

Measure

Required manpower:

: 139 h

* The listed total production time is the rounded sum of the specific absolute time weighted by the required personnel. It
excludes the set-up times for the machine.
** The CAD/CAM works were time-consuming as the supplied data did not represent an ideal 3D surface model.
*** The curing time of the epoxy paste was shortened by heating up the workshop.

Used material
The size of the car (L x W x H) was 4.65 m x 1.90 m x 1.60 m.
Object

Material

Volume*

Net costs

Subconstruction:

Low density styrofoam (PS 30 / density: 27 kg/m)

2 m

160

Carrier material:

Low density styrofoam (PS 30 / density: 27 kg/m)

15 m

1,200

Glue:

Standard PU foam for gluing the styrofoam blocks

20 bottles

170

Paste:

PU and epoxy (EP)**

Approx. 300 l PU

2,700

Approx. 240 l EP

3,360

Approx. total net material costs:

7,590

* Rounded values.
** One half of the car model was extruded with PU paste, the other half with EP paste. The tyres were extruded with PU.

051206

1/5

Used equipment:
Application

Equipment

For milling:

Milling machine: HSM-Modal

Cutters for rough-milling styrofoam: Flat end, 28 mm, 280 mm long

Cutters for finish-milling styrofoam: Ball end, 30 mm, 260 mm long

Cutters for rough-/finish-cutting paste: Bull end, 24 mm, r = 3 mm, 150 mm long

For extrusion:*

1 meter/mix and dispensing machine for EP

1 meter/mix and dispensing machine for PU

* A meter/mix and dispensing machine can either be used for PU or EP paste. Due to chemical incompatibility it is
impossible to use one meter/mix and dispensing machine for both pastes.

Process

051206

Preparatory works: CAD/CAM

Preparatory works: CAD/CAM

Preparatory works: gluing the blocks

Day 1: Milling the styrofoam core

2/5

051206

Day 1: Combining core and blocks

Day 1: Rough-cutting the model

Day 1: Rough-cutting the model

Day 1: Rough-cutting the model

Day 2: Finish-cutting the model

Day 2: Finish-cutting the model

3/5

Day 3: Applying the paste (extrusion)

Day 3: Applying the paste (extrusion)

Day 5: Rough-cutting the extruded model

Day 5: Rough-cutting the extruded model

Day 6: Finish-cutting the extruded model

Day 6: Finish-cutting the extruded model

051206

4/5

Day 8: Extruded tyre

Day 9: Finish-cutting the tyre

Day 9: Readily milled tyre

For further information about this project, please do not hesitate to get in touch with following contact
persons:

EEW Maschinenbau GmbH

Eichkampredder 3
24217 Schnberg
Germany
Mr. Tran
Fon: +49 (0)4344 3055-31
Fax: +49 (0)4344 3055-55
qst@eew-maschinenbau.com

051206

5/5