XTAR Reinvents R&D: In-House Integration of Formlabs Form 4 3D Printers

"100-1=0," seemingly absurd, is Konosuke Matsushita's classic rule: any minor defect can potentially bring brand value to zero. For consumer electronics, quality is paramount. As a global leader in smart chargers, Shenzhen XTAR Electronics Co., Ltd. (XTAR) shares this near-obsessive pursuit of product quality.

When XTAR encountered the Low Force Display™ (LFD) Print Engine, which powers Formlabs Form 4 series masked stereolithography (MSLA) 3D printers, their traditionally lengthy development process transformed. Bringing Form 4 in-house fundamentally changed R&D efficiency, enabling rapid, in-house prototyping that helped XTAR increase the security around their IP. 

Prior to bringing Form 4 in-house, XTAR faced challenges to efficiency, cost, and security. XTAR used traditional processes like mold-making, injection molding, and CNC prototyping, which often led to long R&D cycles. Outsourcing increased the risk of core drawings being leaked during the design verification stage. 

By bringing Form 4 in-house, XTAR no longer needed to rely on outsourcing, saving time and ensuring more control over prototyping and IP. 

Traditional flashlights and chargers have long mold development cycles. By using the Form 4 ecosystem, XTAR engineers can print physical samples for assembly testing within two hours, reducing the prototype verification cycle from several weeks to just a few hours, significantly boosting R&D efficiency.

Prototyping product shells for consumer electronics is crucial. With 3D printing, the XTAR R&D team can quickly iterate on multiple battery charging bay designs and conduct actual product tests. Prototypes printed on Form 4 feature uniform colors, smooth surfaces, and precision up to ±0.05 mm, highly consistent with injection-molded parts, for looks-like, presentation-ready prototypes.

Product shells for electronics printed on Form 4.

Outsourcing prototyping can be risky for companies requiring high levels of confidentiality. By bringing Formlabs 3D printers in-house, XTAR was able to eliminate outsourcing, keeping all core R&D design data in-house. With drawings never leaving the premises and prototypes destroyed on-site, XTAR protected against leaks while simultaneously boosting efficiency.

For XTAR, in-house 3D printing is a strategic tool for breaking design barriers and safeguarding R&D security. In the fiercely competitive consumer electronics market, efficiency and precision are paramount to brand integrity. With Formlabs MSLA 3D printers, XTAR engineers are reducing R&D timelines, efficiently delivering precise prototypes while ensuring IP remains secure.

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