3D Printing for Human Transport

High out: Gravity´s flight suit in action (© Gravity Indsutries)

Based on a recently entered partnership with Gravity Industries Ltd, , EOS GmbH, Krailling, Germany, presented components of Gravity's Jet Suit at formnext in november in Frankfurt, Germany.

Gravity was founded in 2017 with the vision of enabling mankind to fly. The suit of patent pending technology is aiming at revolutionizing human transport, enabling unparalleled human flight. It was built using 3D printed parts, specialist electronics and five jet engines. All components are being developed in an agile and interdisciplinary manner. Full of constant innovation, the suit allows for a 1,000 bhp performance and can fly at a speed of more than 70 km/h.

"For the Jet Suit, Gravity needed high quality parts which offer high part stability and reduced weight as well as enabling constant product iterations and optimization. This is exactly where additive manufacturing comes into play. It offers a true value add as it can inspire companies to change the way they design and manufacture", says Gà¼ngà¶r Kara, Chief Digital Officer (CDO) at EOS.

Arm mount with 3D printed parts, leading to weight an cost reductions by changing material, functional integration and bionic design optimizations (© EOS)

Lighter and Cheaper Thanks to 3D Printed Parts

The companies are cooperating to continuously optimize the Jet Suit based on design optimizations and subsequent additive manufacturing (AM) of relevant parts. Based on the EOS polymer technology, cable routings, electronics and battery housings were produced using AM. For the arm mounts and thrust control, the EOS metal technology is being used. During the joint project, the team was able to achieve substantial cost reductions and a weight reduction of 10 % for the arm mounts by changing from titanium to aluminum material.

Design optimizations can be performed very quickly, as such allowing the realization of quick design iterations. Design for AM led to a consolidation from eight to three parts. At the same time, the number of connecting bosses could also be reduced, lowering the risk of failure. Moreover, the new bionic design enables a lightweight connecting structure. All this also allows for a subsequent simplified assembly.

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This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement Nº 737882.


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