NanoSphere speeds up prototyping with Formlabs Form 4 – 3D printing that changes the pace of R&D
3D printing from silicone? For NanoSphere, it’s already an everyday practice. With the implementation of the Formlabs Form 4 ecosystem, the company has gained the ability to quickly and accurately prototype powder coating masking covers. Check out how mSLA technology has streamlined R&D processes and increased R&D flexibility. The new detailing capabilities and heat resistance of Formlabs Silicone 40A material have allowed engineers to make improvements in a much shorter cycle time. Our implementation included a printer, washer and curing chamber. NanoSphere now handles the entire integrated process, from model to finished part.
About the company
High-tech company
NanoSphere is a high-tech company with a powder coating plant at the center of its operations. They specialize in precision coating of drivetrain components – including automotive half-shafts.
The production plant, located in Praszka, handles several million parts a year, delivering them to end users such as automotive concerns like BMW, GM, Ford and Mercedes-Benz.
The company’s R&D department is responsible not only for supporting the production processes of paint shops, but also carries out projects in the areas of cleaning paint covers, laser ablation and the implementation of innovative material technologies.
NanoSphere uses its own composition of Andromeda powder coatings, constantly developing processes and implementing about 20 new projects per year.
Challenge
Accelerating the prototyping cycle of camouflage covers
In 2025, the company faced the need to accelerate the prototyping cycle of the masking covers used in powder coating.
Until now, the entire design and production process has been outsourced to the company – which meant waiting about six weeks for the first prototypes and up to 10 weeks until the start of mass production.
Outsourcing also entailed the risk of interpretation errors between designers and the subcontractor, as well as a lack of full control over the quality and geometry of components.
NanoSphere needed a solution that would enable rapid, in-house prototyping based on materials with high temperature resistance and flexibility – essential for components used in powder coating processes.
Until now, every design modification meant more weeks of waiting. We were looking for a way to gain more control over the process and prototype on site – quickly, accurately and without compromising on materials.
Wojciech Moćko, Ph.D., Advisor to the Board of Directors for Research and Development at NanoSphere
Solution
Formlabs Form 4 3D printing ecosystem
We at CADXPERT consulted to determine the best path for implementing additive technologies for prototyping. NanoSphere chose to implement the full Formlabs Form 4 3D printing ecosystem, including:
- Formlabs Form 4 printer,
- Automatic Form Wash,
- Form Cure model curing chamber.
The primary selection criterion was the ability to print from silicone, which sets Formlabs’ solution apart from the competition. The mSLA technology used also ensured high-precision reproduction of details in the design of masking and assembly components.
Along with the device, we provided software that makes it easy to design 3D printing supports, hollow out models, and add rating descriptions. The PreForm program from Formlabs accelerated the process of preparing files for 3D printing.
The implementation of Form 4, by design a plug-and-print device, required only one day of training. The R&D engineering team on the NanoSphere side practically operated the entire system on its own from the start.
With an integrated ecosystem including printing, washing and curing, NanoSphere has gained a complete 3D printing process, ready for research applications.
Form 4 from CADXPERT has proven to be a complete solution. It’s equipment that simply works and produces the results we need.
Wojciech Moćko, head of research and development, NanoSphere
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- Descriptions of the characteristics of 3D printing technologies.
- Comparison of 3D printers from different manufacturers by market segment.
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Results
3D printer gripper
With printer Formlabs Form 4 working with material Formlabs Silicone 40A NanoSphere has reduced its prototyping cycle from 6 to 4 weeks. The company now prints 4-6 variants simultaneously in a single cycle, maintaining full control over design and component quality.
The silicone material used meets the process requirements – it is flexible and can withstand temperatures up to 180°C, which is ideal for the conditions in a powder coating plant. The R&D department can now test new masking solutions almost immediately (printing takes a few hours) after they are designed.
Internal prototyping also reduced communication errors and eliminated the need for corrections due to inconsistencies between drawings and the actual model.
The NanoSphere team also plans to use Form 4 to design service parts, nozzles, gaskets and inspection jigs, supporting maintenance and daily production operations.
There are plans to expand the use of 3D printing to include new materials and applications. With CADXPERT’s support, NanoSphere has gained equipment, but also a full engineering process that increases the flexibility of operations and speed of deployments.
The effects of implementation in a nutshell:
- Reduce prototyping cycle from 6 to 4 weeks
- Full quality and geometry control of models
- Simultaneous printing of up to 6 projects
- Resistance of models to temperatures up to 180°C – ideal for powder coating processes
- Implementation and training completed in 1 day
- Increase the efficiency and autonomy of the R&D department
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