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The moment you see a full scale Seaglider mockup at the Dubai Airshow, the first thought is: “Can this really be 3D printed?” a fair question indeed. In exhibitions, 3D printing is usually reserved for scaled down models, NOT a 1:1 mockup with full interiors you can actually walk into. This is the first time something of this scale has been ever produced through 3D printing anywhere in the world!

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Proto21 has built its reputation on redefining what additive manufacturing can achieve. Earlier this year, we broke the Guinness World Record for the largest 3D-printed structure by volume at MYATA Restaurant. Alongside that, Proto21 has delivered several other complex, first of their kind largescale models that continue to push the boundaries of the 3D Printing industry.

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The UAE ecosystem is a unique ground where professionals from around the world showcase their highest level of skill and technology. It is a place where innovation is not only encouraged, it is pushed to new limits by a leadership that constantly aims higher. Opportunities here are unlike anywhere else… where else would anyone ask you to produce a full-scale mockup entirely through 3D printing? UAE doesn’t just adopt the future, it builds it.

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About REGENT Viceroy Seaglider

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Regent Viceroy Seaglider is a 12 passenger vehicle that operates exclusively over water with speeds of up to 290 km/h, traversing the sea in one of three modes: hull, hydrofoil, or flight in ground effect. Seaglider is equipped with innovative electric technology, promises to cut travel time between Dubai and Abu Dhabi is expected to be only 30 minutes at a cost of around AED 165. That’s quicker than a helicopter and cheaper than a taxi. 

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Role of Proto21(3D Printing) in Bringing the Seaglider to Life

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Our expertise in large scale 3D printing technology has enabled us to produce such massive projects. Our team can handle such massive assembly processes in support of Joseph Group, integrating structural elements and ensuring a seamless finish. To produce such a massive structure, advanced 3D printing technologies are utilized including Robotic Arm (LFAM) and Fused Deposition Modeling (FDM) technology with industrial grade materials, engineering excellency and passion we hold.

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Technical Details

• The seaglider mockup measures 16 meters in length with a 12 meter long wing, and represents the world's largest 3D Printed exhibit.

• The structure comprises a total consolidated volume of 23.5 m³, combining advanced biodegradable polymer 3D printed sections with a precision-engineered internal metal support frame to ensure structural rigidity throughout the model.

• The project was completed within an accelerated three month production timeline, leveraging the full capabilities of Proto21’s in-house Additive Manufacturing Division, including FDM Farm, LfAM, and SLA technologies.

• Across the production cycle, 260 printers were used comprised of Caracol AM System, PrusaLab & Bambu Lab, extruded approximately 2.2 tonnes of polymers, forming the outer aerodynamic surfaces and internal geometry.

• 29,600 hours of 3D printing and 3,200 individual 3D printed pieces were 3D utilized to complete the project.

• 980 design engineering hours and 8,300 skilled men hours were utilized to complete the project.

• The mock-up was fabricated as a series of strategically segmented Sections  ( Viz. Nose, Cabin, Wing, tail etc, engineered for accuracy, transportability, and rapid assembly and disassembly. These sections were subsequently integrated around the metal structure to deliver the final seamless full-scale Sea Glider representation.

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Interior of the Seaglider

The interior of the Seaglider was designed to immerse visitors in a futuristic, luxury travel experience. All the details inside the cabin were crafted with accuracy, ensuring the mockup reflected the real vision of REGENT’s next-generation passenger vessel.

• Cove lighting and spot lights were installed.

• A dedicated luggage compartment was built to demonstrate practical passenger storage.

• Customized leather seats with an embossed REGENT logo were produced.

• Flooring and furnishing were installed.

• A cockpit simulation display was integrated to showcase the pilot’s perspective, helping visitors understand the Seaglider’s operational interface.

• Window display artworks were added to simulate real exterior views.

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‍Joseph Group’s Contributions

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The success of the mockup, however, was not achieved by Proto21 alone. It was the result of a coordinated effort by the Joseph Group, where both subsidiaries brought unique skills to make this milestone possible. Joseph Projects and Traffic Signs managed load calculations and metal structures, ensuring the mockup could safely maintain its form. Joseph Graphics delivered branding and livery, giving the sea glider its eye-catching exterior. Joseph Digital Solutions installed LED screens inside the cabin, enhancing the futuristic feel of the interior. Joseph Industries provided finishing and paintwork services, while Joseph General Maintenance managed the logistics and installation, making sure the massive structure was safely transported at the Airshow.

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Conclusion

In conclusion, the full-scale REGENT Seaglider mockup is a perfect example of how creativity, technology, and teamwork intersect to push the boundaries of what’s possible. It’s a statement that bold ideas, when combined with expertise and collaboration, can transform the impossible into reality. Visitors at the Dubai Airshow didn’t just see a model; they witnessed a glimpse of the future of mobility, innovation, and 3D printing.

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