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Varying calcination temperature maximized formate production via optimizing the crystallinity and particle size of the constituent SnO<sub>2</sub> nanoparticles. The best performing SnO<sub>2</sub> nanosphere catalysts contained\u2009~\u20097.5\u00a0nm nanocrystals and produced 71-81% formate Faradaic efficiency (FE) between -0.9\u00a0V and -1.3\u00a0V vs. the reversible hydrogen electrode (RHE) at a maximum formate partial current density of 73\u2009\u00b1\u20092\u00a0mA cm<sub>geo</sub><sup>-2</sup> at -1.3\u00a0V vs. RHE. The higher performance of nanosphere catalysts over SnO<sub>2</sub> nanoparticles and commercially-available catalyst could be ascribed to their initial structure providing higher electrochemical surface area and preventing extensive nanocrystal growth during CO<sub>2</sub> reduction. Our results are among the highest performance reported for SnO<sub>2</sub> electrocatalysts in aqueous H-cells. We observed an average 68\u2009\u00b1\u20098% FE over 35\u00a0h of operation with multiple on/off cycles. In situ Raman and time-dependent X-ray diffraction measurements identified metallic Sn as electrocatalytic active sites during long-term operation. Further evaluation in a 25 cm<sup>2</sup> electrolyzer cell demonstrated impressive performance with a sustained current density of 500\u00a0mA cm<sub>geo</sub><sup>-2</sup> and an average 75\u2009\u00b1\u20096% formate FE over 24\u00a0h of operation. 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