Ricoh 3D and Gravity Industries Power Electric Jet Suit with Polypropylene 3D Printing: The Future of Human Flight Takes Off

In a groundbreaking collaboration set to redefine personal aerial mobility, Ricoh 3D has once again joined forces with the visionary Gravity Industries. This renewed partnership marks a significant leap forward, focusing on the production of Gravity’s ambitious new project: the Electric Jet Suit. Following four years of unparalleled success with Gravity’s original Jet Suit, which captivated audiences worldwide, the companies are now channeling their collective expertise into an electric variant. This cutting-edge suit is poised to make its highly anticipated debut at the illustrious 2021 Goodwood Festival of Speed, promising to deliver a fresh perspective on human flight. The technical cornerstone of this innovative endeavor lies in Ricoh 3D’s advanced proficiency in polypropylene (PP) technology, which is proving instrumental in transforming this ambitious vision into a tangible reality.

The synergy between Ricoh 3D and Gravity Industries has consistently pushed the boundaries of what is conceivable in personal flight. Their initial partnership saw the rapid development and global deployment of the original Jet Suit, a marvel of engineering that allowed individuals to truly experience unencumbered flight. This collaboration demonstrated that human flight gear could be not only groundbreaking but also commercially viable. Gravity Industries has, over the past few years, showcased their revolutionary Jet Suit technology across 33 countries, conducting critical Search & Rescue trials, offering advanced commercial flight training, and even participating in high-profile racing events like Top Gear. The ability to combine Gravity’s innovative and daring designs with Ricoh’s flagship material, polypropylene, proved to be a winning formula. This material choice allowed for the creation of a Jet Suit flight experience that was both supremely comfortable and rigorously safe, all while maintaining an impressively cost-effective production model. The success of this initial venture laid a solid foundation for the ambitious transition to an electric version, promising even greater efficiency and sustainability.

The decision to develop an Electric Jet Suit represents a pivotal moment in the evolution of human flight technology. This electric iteration is expected to offer a quieter, more environmentally friendly, and potentially more accessible form of personal aerial mobility. By leveraging Ricoh 3D’s mastery of polypropylene, the new suit aims to enhance the inherent advantages of the original design while incorporating the benefits of electric propulsion. Sam Rogers, Gravity’s Chief Designer, eloquently captures the essence of this innovation: “Thanks to polypropylene and its organic nature, people see a human who is flying when someone is in the Jet Suit. They aren’t strapped into a device or seated in a vehicle; they appear to be genuinely flying, and it’s that distinction that makes all the difference.” This perspective underscores how the material science behind the suit contributes not just to its functionality but also to its profound psychological impact, fostering a perception of natural, unassisted flight that resonates deeply with observers and pilots alike. The choice of polypropylene is thus critical, enabling a design that feels less like a machine and more like an extension of the human body, blurring the lines between man and machine in the most inspiring way.

(Photo Credit — Instagram: @richardmbrowning, Founder & Chief Test Pilot at Gravity Industries)

Benefits of Using Polypropylene (PP) in Advanced 3D Printing

Polypropylene (PP) stands out as one of the most widely utilized thermoplastics across various industrial sectors, and its application in 3D printing, especially for the demanding requirements of a human flight suit, highlights its exceptional versatility. Among polypropylene’s primary benefits are its remarkably low price point, making it an economically attractive choice for advanced manufacturing. Its lightweight nature is crucial for any aerial vehicle, directly contributing to enhanced maneuverability and reduced energy consumption. Furthermore, PP exhibits low friction, resulting in a relatively slippery surface, which can be advantageous for aerodynamic designs and reducing wear. Beyond these physical characteristics, PP boasts impressive performance attributes. It is highly chemical-resistant, hydrophobic (meaning it repels water), possesses excellent impact resistance, and offers superior electrical insulation. These properties are critical for ensuring the safety and durability of the Jet Suit, especially in varied environmental conditions and for protecting sensitive electronic components.

The robust properties of polypropylene make it an ideal candidate for pushing the boundaries of engineering. Mark Dickin, Head of Ricoh European 3D Printing Operations, emphasizes this, stating, “The Jet Suit is a testament to the tenacity of engineering. By pushing the boundaries with both 3D printing and polypropylene, we’re showcasing what’s possible when you have the right expertise and ingenuity.” He elaborates on the material’s benefits, highlighting its eco-friendliness and high performance: “3D printed polypropylene is 90% recyclable, lightweight and flexible while still being incredibly durable—ideal for taking to the skies.” This combination of attributes ensures that the Jet Suit is not only functional and safe but also aligns with modern sustainability goals. A significant advancement brought about by 3D printing with PP is the drastic reduction in production time and complexity. Previously, custom building the core Suit structure using traditional methods, involving aluminum riveting and manual bolting, would take more than two weeks. With Ricoh 3D’s additive manufacturing processes, print time for these complex components is now just 24 hours, slashing the overall assembly time from over two weeks to merely two days. This unparalleled speed allows for rapid iteration, continuous improvement, and much faster deployment of new designs, fundamentally transforming the development cycle for cutting-edge flight technology.

The strategic integration of 3D printing has profoundly simplified the production process for Gravity’s Electric Jet Suit. This additive manufacturing approach eliminates the need for producing hundreds of costly and time-consuming physical prototypes typically required in traditional manufacturing. Instead, engineers can make incremental adjustments and refinements to designs between iterations with unparalleled ease and speed. This agility means there’s no longer a need to commission all-new moldings or endure the repetitive, time-consuming delays associated with starting from scratch for each design modification. As an additive manufacturing material, polypropylene offers the distinct advantage of being perfectly suitable for use as both a prototyping material and, crucially, as the material for the final, end-use parts. This seamless transition from concept to production part streamlines the entire development pipeline and significantly reduces costs.

Richard M. Brown, Founder & Chief Test Pilot at Gravity Industries, underscores the profound impact of 3D printing on the Jet Suit’s design and functionality: “The design freedom of 3D printing reduces the Suit’s part-count significantly by consolidating several assemblies into one, with far fewer components to glue and bolt than would be necessary with other manufacturing methods.” This part consolidation not only simplifies assembly but also inherently increases the structural integrity and reduces the overall weight of the suit, directly translating to improved flight performance and safety. Furthermore, Brown highlights PP’s capability to enable sophisticated, multifunctional components: “Polypropylene also makes it possible to create multifunctional components, with lots of internal flow parts which move air through the Suit to keep it cool.” This advanced design capability, achievable only through additive manufacturing, allows for complex internal geometries that are vital for thermal management, ensuring pilot comfort and equipment reliability during sustained flight. The ability to integrate such intricate functionalities into single, lightweight components is a game-changer for high-performance human flight systems. To delve deeper into this exciting partnership and the advancements behind Gravity Industries and Ricoh 3D’s electric Jet Suit, you can learn more HERE.

The collaboration between Ricoh 3D and Gravity Industries represents more than just the creation of an advanced flight suit; it signifies a monumental leap in the application of 3D printing and material science to challenging engineering problems. The Electric Jet Suit, powered by the innovative use of polypropylene, is a testament to what can be achieved when cutting-edge technology meets audacious human ambition. It paves the way for future innovations in personal mobility, emergency response, and even competitive sports, offering a tantalizing glimpse into a world where human flight is not just a dream but an increasingly practical reality. This project is not merely an engineering feat but an inspiration, showcasing how sustainable, rapid manufacturing can accelerate the realization of truly transformative technologies.

What are your thoughts on Gravity Industries and Ricoh 3D’s pioneering use of polypropylene and 3D printing in their partnership to create the Electric Jet Suit? Share your insights and join the conversation by leaving a comment below, or connect with us on our Facebook and Twitter pages. Don’t miss out on the latest advancements in additive manufacturing—remember to sign up for our free weekly newsletter, delivering all the essential news in 3D printing directly to your inbox!

Cover Image Photo Credit — Instagram: @richardmbrowning, Founder & Chief Test Pilot at Gravity Industries