Wingsuit Product Development | Phoenix Fly

Concept Design

The development process simply begins with an idea. This idea is then fleshed out with sketches and scaled drawings. The mission that the product is destined to fulfill is carefully considered from concept through production.
We incorporate valuable feedback that is supplied to us by the world’s best trackers and wingsuit pilots, as well as from our body of customers around the world.  

Research and Development

2D flow simulation software is used to assist in wing profile selection and design optimization. The results of these tests may inspire us to make adjustments and base design alterations, so this is usually an iterative part in the process. For our more complex products and components, such as the arm wing of the Vampire V-3 for example, CAD software is utilized to help realize the complex 3D forms required to provide superior flight characteristics.

Phoenix-Fly is continually looking for new materials and technologies to incorporate into our products, such as the Dacron and Mylar used on the Vampire range of wingsuits.

Prototype and Testing

Once the design is completed on paper, the first prototype is created and tested. Robert and our team of test jumpers assess all aspects of the new design; performance, durability and comfort are all evaluated to ensure we build a premium product. 

Industrialization

Once the wingsuit design has been finalized, the industrialization process begins. This is an extremely critical and challenging process. The Vampire 3 is made up of nearly 300 separate components and templates which must be individually produced for each suit.

Manufacture

Our wingsuits are produced in Slovenia, by Atair Aerodynamics (manufacturer of the Troll and Radical canopies). Phoenix-Fly suits are built with the same exceptional standards that are applied to canopy-building, a difference that is immediately noticed when you pick up one of our wingsuits.

Our resident aerodynamics expert and owner of Atair Aerodynamics, Stane Krajnc, assists in the design and testing stages of the development cycle. His proficient knowledge of aerodynamics is based not only on his academic knowledge, but also on 30 years of experience in air sports, including hang-gliding, paragliding, skydiving and BASE jumping.

Quality Control

All Phoenix-Fly products go through a rigorous quality control check before they are sent to the customer. In the case of the Vampire 3, 100% of the suits are additionally personally checked by Robert before dispatch.