3D Scan, Design & Print: OEM-Style N90 Hilux Switch Panel
Designed from Scratch. Built to Look Factory.
The Challenge
When the new N90 Toyota Hilux hit the Australian market, there was one problem for owners looking to fit accessories: there wasn't a clean, factory-style switch panel available.
Our sister company, Overland Tourers Australia (OTA), wanted to change that.
Their goal was simple. Develop a premium switch panel that looked like it belonged in the vehicle from the factory while giving owners an easy way to install auxiliary lighting, air compressors, UHF radios, winches and other 12V accessories without cutting or drilling into the dash.
Being first to market with a new vehicle platform creates a huge opportunity, but only if the product is right. Speed and quality needed to go hand in hand.
Starting with a Blank Canvas
Because the N90 Hilux was so new, there were no existing CAD files or aftermarket products to work from.
We began by 3D scanning the factory dash insert beneath the driver's side cup holder using our high-resolution scanner. This captured every mounting clip, contour and locating feature, giving us the foundation to build an accurate CAD model.
From there, we designed a complete replacement panel from the ground up.
The finished design accommodates up to five standard 22 mm push-style switches, along with a dedicated port that can be configured for either an RJ45 UHF passthrough or a USB accessory input. Every mounting feature was designed to mirror the factory panel, allowing for a straightforward installation with no cutting or permanent modifications.
Prototyping for the Perfect Fit
Before moving into production, we produced several prototypes to validate the design inside a genuine N90 Hilux. This allowed us to fine-tune clip engagement, switch spacing and overall panel alignment before committing to the final material. Because this panel sits in one of the most visible areas of the cabin, surface finish was just as important as dimensional accuracy.
For this reason, we selected SLA printing on our Formlabs Form 4L. The process delivers exceptional detail and allowed us to reproduce the factory-style leather grain texture while maintaining the tight tolerances needed for OEM-quality fitment.
Once the prototypes were approved, we moved straight into production.
The Final Product
The completed switch panel is manufactured using durable black SLA resin and finished with an OEM-inspired leather grain texture that blends seamlessly with the factory dashboard.
Designed as a direct replacement for the original dash insert, installation is completely reversible and requires no cutting or drilling.
Owners can install up to five push-style switches alongside an RJ45 or USB port, creating a clean and organised solution for powering the accessories they actually use.
Rather than looking like an aftermarket add-on, the finished panel looks exactly how it should have left the factory.
From Concept to Market
The switch panel is now available through Mick Tighe 4x4 & Outdoor under the Overland Tourers Australia range, joining the existing Next Gen Ranger and 250 Prado switch panel lineup.
Projects like this highlight the advantage of combining 3D scanning, CAD design and additive manufacturing. Instead of waiting months for tooling or overseas production, we were able to design, validate and manufacture a production-ready automotive product locally, helping OTA become one of the first companies to offer a dedicated switch panel for the new N90 Hilux.
Have an automotive product idea?
Whether you're developing a new accessory or improving an existing design, Forma 3D can help bring it to life. From 3D scanning and CAD design through to prototyping and production, we help businesses get products to market faster.
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Email: admin@forma3d.com.au
Phone: (07) 4588 6659