Tactical Dehydration in Fighter Pilots: 3D Printing Solutions for Enhanced Readiness

In the high-stakes world of fighter aviation, the threats aren't always visible on radar. One of the most dangerous liabilities a pilot can face is also one of the least discussed: dehydration. Tactical dehydration—when pilots intentionally limit fluid intake to avoid the logistical nightmare of mid-flight urination—has long been an unspoken compromise, especially for female fighter pilots. But that silence has had consequences.

“We have lost pilots and aircraft multiple times to G lock,” says Jennifer West, PhD(c), former Air Force Captain and now Medical Advisor for the Los Angeles-based startup AIRION. G lock, or G-force-induced Loss of Consciousness, occurs when a pilot’s body can’t maintain enough blood flow to the brain under extreme acceleration. Staying hydrated helps prevent it, but the discomfort—and for many women, the impossibility—of relieving oneself in flight discourages even the most seasoned aviators from drinking enough water before or during missions.

Recognizing the critical danger posed by this issue, AFWERX—the innovation wing of the Air Force and Air Force Research Laboratory—launched a challenge in 2021 to develop a viable, in-flight bladder relief system for female pilots. The stakes were high: decades of makeshift solutions and unmet needs had left a glaring gap in pilot safety. Enter AIRION.

Despite competing against major defense contractors with deep pockets and long resumes, AIRION, a small startup with no legacy systems to build from, clinched the award. Their secret? Starting from scratch. “We didn’t see anything on the market that worked. It had to be designed completely anew,” explains Justin Jacob, Chief Engineer at AIRION.

Rather than retrofit existing equipment, the team leaned into a design-first philosophy. That meant rapid iteration, tight collaboration with active duty pilots, and constant adaptability. Each prototype was refined based on real-time feedback from the end users. As the team shifted focus across aircraft models—from A-10s to F-35s—the requirements changed too. That meant every piece of gear needed to be optimized for different harness configurations, cockpits, and mission types.

This high-speed, high-stakes innovation cycle required a nimble fabrication strategy. Traditional outsourcing methods were too slow and expensive. The solution came in the form of selective laser sintering (SLS) 3D printing technology, which allowed AIRION to print durable, flexible components in-house, often within a single day. “We needed to be able to test parts that same afternoon,” says Jacob. “Outsourcing just wasn’t an option anymore.”

They ultimately adopted the Fuse Series of SLS printers from Formlabs, a decision that proved critical. The AIRUS device—AIRION’s flagship solution—uses TPU 90A Powder for its primary contact components, chosen for its flexibility, durability, and skin-safe biocompatibility. ISO-certified for non-toxicity, the material met stringent military and medical standards. The rest of the device’s internal mechanics were printed in Nylon 12 Powder to ensure structural integrity, tight seals, and resilience under extreme stress.

Testing wasn't limited to the lab. Devices underwent grueling real-world assessments, including installation and removal in confined cockpits, exposure to extreme vibration and temperature shifts, and repeated stress cycles. From package to pilot, the AIRUS had to survive the full lifecycle of a combat mission.

Today, the AIRUS is available in five sizes, with more in development—including a system for male pilots, a demand that emerged from unexpected quarters once the success of the female-focused design became clear. With production scaling rapidly, AIRION has added multiple printers and round-the-clock manufacturing schedules to meet military demand. Their small-batch, modular production model aligns neatly with the Air Force’s N+1 redundancy doctrine, ensuring there’s always a backup unit ready to fly.

But perhaps most notable is how AIRION’s story exemplifies a broader shift in defense innovation: one that values agility over incumbency, and design thinking over bureaucracy. Winning the AFWERX challenge wasn’t just about building a better product—it was about proving that small, mission-focused teams can outpace even the most established industry giants when lives are on the line.

And for the pilots flying under crushing G-forces at the edge of human endurance, the payoff is more than technical. It’s personal. “For nearly three decades, our female aviators have had to rely on uncomfortable and potentially risky options just to relieve themselves,” says West. “It’s more than an inconvenience. It’s about safety, dignity, and finally being heard.”

AIRION’s innovation began with a simple premise: if no solution exists, make one. Today, that premise is saving lives at 30,000 feet.