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Allison Transmission – 2000 Series 3D Model Precision Manufacturing

Table of content

01 The Project Brief
02 Technical Context — Allison 2000 Series
03 Scope of Work - 3D Miniature Engineering
04 Production Challenges & Solutions
05 Project Outcomes
06 Impact
07 Conclusion

The Project Brief

Allison Transmission, a global leader in fully automatic transmission systems, commissioned ARC to design and fabricate high-fidelity scale models of its 2000 Series — a core product line in the company’s light and medium-duty commercial fleet portfolio.

The original 2000 Series transmission is deployed extensively in urban delivery trucks, small to mid-sized buses, and specialty vocational vehicles. Weighing approximately 15,000 kilos in its operational configuration, it is engineered to optimize torque handling capacity, improve power-to-weight ratio, and deliver seamless gear shifting for high-performance, fuel-efficient operation.

The miniature was to serve as a scaled engineering showcase — accurately reflecting the geometry, surface topology, and mechanical architecture of the real unit — while being small enough to function as a premium display piece for Allison’s top performers.

Technical Context — Allison 2000 Series

Application Range : Light and medium-duty fleets, including commercial trucks, school buses, and small coaches.
Core Function : Enhances torque multiplication for higher-powered vehicles in a lightweight, compact housing.
Design Engineering : Planetary gearsets, advanced clutch packs, and optimized hydraulic circuits.
Operational Benefits : High torque-to-weight efficiency
Reduced maintenance intervals via self-diagnostic features
Smooth, automatic shifting under varying load conditions

Brand Significance: The 2000 Series is a flagship product family – representing Allison’s expertise in precision engineering, advanced metallurgy, and mechatronic control systems.

Scope of Work - 3D Miniature Engineering

Data Acquisition & CAD Modelling

Translated Allison’s OEM engineering blueprints into parametric 3D CAD data.
Applied reverse engineering principles to proportionally downscale the model while maintaining dimensional fidelity.

Surface Detailing & Geometry Optimization

Developed accurate CAD geometry to replicate transmission casing contours, bolt patterns, and gear housing features.
Included fine-scale representation of planetary gear outlines and cooling fin architecture.

Manufacturing Methodology

SLA 3D printing using ABS-like resin at 50-micron layer resolution to capture intricate component detailing such as control modules, actuator housings, and fastening points.
Metallic silver paint finish, hand-applied in multiple layers to replicate the alloy’s industrial appearance with realistic shading and depth.

Branding & Presentation

Each baseplate was SLA printed with embossed lettering and model identification details, ensuring the branding was integral to the print itself.
Delivered in a foam-lined magnetic closure display box for safe transit and premium presentation.

Production Challenges & Solutions

Micro-Detail Preservation: Leveraged 50-micron SLA print resolution to maintain accurate blade edges, bolt heads, and gear tooth definition.
Material Fidelity: Chose ABS-like resin for its high strength, dimensional stability, and smooth surface quality.
Surface Finish Quality: Applied metallic silver paint finish in controlled layers to simulate the look of machined alloy surfaces.
Deadline Compliance: Parallelized SLA print runs and painting workflows to ensure all 50 units were ready ahead of schedule.

Project Outcomes

Delivered all 50 precision 3D models ahead of schedule with zero quality deviations.
Achieved 98%-dimensional accuracy compared to the scaled OEM CAD reference.
Enhanced employee recognition through a tangible representation of Allison’s engineering excellence.
Models now serve as permanent display assets in executive offices and engineering centres.

Impact

Engineering Brand Storytelling:The miniature allows employees and visitors to physically engage with the 2000 Series architecture in a desk-friendly, highly accurate form.
High-Value Recognition: Provided award recipients with a collector-grade technical artifact, symbolizing their contribution to Allison’s legacy.
Versatile Deployment: Potential to use the model as a trade show exhibit giveaway, OEM partner gift, or internal training visual aid.

Conclusion

This project demonstrated ARC’s capability to merge SLA 3D printing with ABS-like resin, 50-micron resolution detailing, and premium metallic paint finishing into a single high-impact deliverable.

By transforming the 15,000-kilo Allison 2000 Series transmission into a desktop-scale, engineering-accurate 3D model, ARC reinforced the idea that brand value is best conveyed when innovation can be held in the palm of your hand.

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