Fast, Affordable, Full-Scale Automotive Part Prototyping with 3D Printing in Australia
How OTA Fast-Tracked Development with Local 3D Printing
When OTA (Overland Tourers Australia) needed to prototype a new flare for the Prado 250 Series, they faced a familiar challenge — time and cost. Previously, their prototyping process was outsourced overseas, resulting in long delays and inflated expenses. This time, they turned to Forma 3D for a fast, local solution — and we delivered.
Customer Inquiry – The Problem
OTA approached Forma 3D with a request for multiple full-size prototypes of their newly designed 250 Series flare. With international options proving slow and costly, they were looking for a streamlined, Australian-based solution to speed up their development cycle without sacrificing quality.
“Speed was everything for this project. We needed a test-fit prototype without the 3-week wait.” — OTA Team
Initial Action – Getting to Work
After receiving the STL files, our team loaded them into our slicing software and conducted a swift design review. Once we confirmed the print parameters were accurate, we prepped the files for production.
Our priority at this stage was dimensional accuracy, ensuring the prototype would serve as a reliable base for final tooling and manufacturing decisions.
R&D & Prototyping – Printing at Scale
The prototypes were printed on our Elegoo Orangestorm Giga, a large-format printer perfectly suited for oversized automotive parts.
We selected PLA as the print material — a cost-effective, efficient option ideal for prototyping.
Each flare was printed in halves, then glued together to create a full-size model. While segmentation was necessary due to part size, the process still achieved the desired result quickly and accurately.
Final Product – Ready for Test Fit
Once printed and assembled, the prototype was delivered to OTA for test fitting.
The full-scale model allowed them to assess clearances, mounting points, and the overall shape before moving into vac forming and tooling.
“Having this prototype in our hands within days meant we could move straight into the next stage of development. Massive time-saver.” — OTA Team
Outcome – Fast, Cost-Effective, Local
This project highlights how local 3D printing can eliminate long lead times, reduce costs, and fast-track product development. OTA was able to validate their design within days — not weeks — and take a major step forward in their production process.
Need a large-scale prototype, fast?
📩 Get in touch with Forma 3D to bring your next idea to life — big or small.
👉 hello@forma3d.com.au