Manufacturing End-Use Automotive Components with SLA 3D Printing in Toowoomba
How We Accelerated & Enhanced OTA Ranger Switch Panel Production Using In-House SLA Technology?
At Forma 3D, we recently supported our sister company Overland Tourers Australia (OTA) with the production of their Next Gen Ranger switch panels. With demand growing, the goal was to improve turnaround times, maintain a premium surface finish, and keep production entirely local. Using our Formlabs Form 4L SLA printer, we delivered durable, high-detail panels — printed in-house right here in Toowoomba, Queensland.
Project Brief – Faster Turnaround, Better Finish, Made Local
OTA needed a more efficient way to produce high-quality switch panels for the Ford Next Gen Ranger. Their previous methods were slower, more expensive, and not well-suited for scale. With the addition of our SLA printing capabilities, Forma 3D was able to offer a faster, cost-effective solution — all produced in-house in Toowoomba with full control over quality, surface finish, and turnaround times.
Initial Action – Choosing the Right Tool for the Job
This project was ideal for our Formlabs Form 4L, which uses Stereolithography (SLA) to create solid, high-detail parts with an exceptional surface finish. Unlike traditional FDM printing, SLA produces smooth, professional-looking components — great for customer-facing products like interior panels. And by keeping production in Toowoomba, we could move fast and stay agile.
R&D & Prototyping – Seamless Setup and Surface Control
OTA provided the print-ready files, and we prepped them using PreForm, Formlabs’ slicing software. This allowed us to apply a textured surface finish that visually matched the Ranger’s interior. No CAD or scanning was needed — just smart file prep and high-performance SLA tech. The process was clean, fast, and repeatable.
Final Output – Ready to Fit, Straight Off the Printer
We selected Black Resin, a tough, production-grade SLA material with a clean matte finish. The result was a sleek, functional panel ready for install — no post-processing or external tooling required. Most importantly, the new process significantly reduced production time while improving part quality.
Outcome – In-House Speed, OEM-Like Finish
The outcome? Faster production, lower costs, and better consistency — all under one roof. OTA was able to test, iterate, and scale their production without relying on external suppliers or overseas delays. With multiple switch panel designs in development, this process will now serve as a blueprint for future parts.
“These came out perfect. The surface finish and speed of turnaround were exactly what we needed.” — OTA Team
Looking to manufacture parts with a premium finish — locally and fast?
Pop into our 11 Mort Street, Toowoomba showroom or contact the team to learn more about our SLA printing services.
admin@forma3d.com.au
(07) 4588 6659