Gravity Industries partnered with Prototal to redesign and optimize a critical component of its Jet Suit: the turbine arm mount. By applying Industrial 3D Printing, the collaboration delivered a lighter, more efficient design with consolidated parts, improved geometry, and enhanced performance—supporting longer, faster, and more controlled human flight.
Gravity Industries is a UK-based technology company redefining human flight. Through a portfolio of patented technologies, the company has developed the Gravity Jet Suit, enabling controlled, vertical take-off and sustained flight through a unique integration of human movement, advanced propulsion, and wearable engineering. Gravity’s vision is to create a seamless collaboration between mind, body, and machine, pushing the boundaries of what personal aviation can achieve.
The Challenge: Reducing Weight and Improving Efficiency
As the Jet Suit evolved, Gravity Industries identified the need to reduce weight and optimize the design of the existing turbine arm mount. This component plays a crucial role in both performance and pilot control, meaning any redesign had to meet strict requirements for:
- Low weight
- Structural strength and durability
- Efficient load distribution
- Compact, highly optimized geometry
Traditional manufacturing methods limited design freedom and material efficiency, making it difficult to achieve the next level of performance.
The Solution: Industrial 3D Printing
Gravity Industries partnered with the Prototal site in the UK to explore how Industrial 3D Printing could unlock new design possibilities.
Through close collaboration, Industrial 3D Printing enabled:
- Complex, topology-optimized geometries
Material was placed only where structurally required, improving strength-to-weight ratio. - Part consolidation
Multiple components were combined into fewer printed parts, simplifying assembly and reducing failure points. - Lightweight, streamlined design
The redesigned turbine arm mount significantly reduced mass while maintaining structural integrity. - Faster design iteration
Industrial 3D Printing allowed rapid refinement and continuous improvement without tooling constraints.
Results: Performance Gains Through Design Freedom
The transition to Industrial 3D Printing delivered tangible benefits for the Jet Suit platform:
- Reduced component weight
- Improved aerodynamic and structural efficiency
- Simplified assembly with fewer parts
- Enhanced overall flight performance
By optimizing geometry and material usage, Gravity Industries achieved a more efficient design—enabling longer flight times and higher speeds.
“With rapid innovation comes the need to work with companies that can respond just as quickly. Collaborating with Prototal allows us to work with a highly capable and motivated team as we continuously improve the Jet Suit design.”
– Gravity Industries
For Gravity Industries, Industrial 3D Printing has become a key enabler of innovation—supporting lightweight design, rapid iteration, and performance-driven engineering. The collaboration with Prototal UK demonstrates how additive manufacturing can transform highly demanding, cutting-edge applications where every gram matters.
Do you want to know how your project could benefit from Industrial 3D Printing? Contact us today to figure out!
