Proto21 leveraged Heron AM to 3D print a full-scale Seaglider mockup for REGENT Craft in UAE

Caracol’s LFAM technology Heron AM was integrated by Proto21 in the production of the world’s largest 3D-printed aviation mockup, a 16-meter-long Seaglider unveiled at the Dubai Airshow. Produced for REGENT Craft, the project stands out as a new iconic benchmark, showcasing the power of robotic LFAM to accelerate innovation within the mobility sector.

The project involved the production of a full-scale (1:1) mockup of the REGENT Viceroy Seaglider, a next-generation electric vehicle designed to operate over water. The manufacturer, Proto21, is a UAE-based leader in large-scale additive manufacturing, known for delivering record-breaking and highly complex 3D printed structures. The challenge was unprecedented: producing a 16-meter-long structure with full interiors, entirely through additive manufacturing, within a tight timeline and with exhibition-level finish.

Caracol’s robotic LFAM technology for composite part manufacturing, Heron AM, was selected by Proto21 to contribute to the production of this outstanding full-scale mockup. Heron AM was adopted to produce the largest components, primarily the external shell of the structure: it enabled the rapid production of highly customized parts without the use of tooling or molds, while significantly minimizing manual intervention. In addition, the ability to manufacture large monolithic sections reduced the total number of components, consequently lowering assembly complexity and time.

The REGENT Seaglider: design, structure and mockup production

The REGENT Viceroy Seaglider is a 12-passenger, all-electric vehicle designed to operate over water in hull, hydrofoil and ground-effect flight modes, reaching speeds of up to 290 km/h. Conceived to enable ultra-fast regional connections – such as Dubai ↔ Abu Dhabi in approximately 30 minutes at an estimated cost of around AED 165 – It represents a new paradigm in high-speed, sustainable coastal mobility. The full-scale mockup accurately reproduces the final product’s external geometry and interior layout, offering an immersive preview of a futuristic luxury mobility experience. The structure was developed using a modular, segmented approach to enable efficient transport and rapid on-site assembly.

Production leveraged a combination of advanced additive manufacturing technologies, including large-format robotic LFAM systems such as Caracol’s Heron AM, alongside industrial FDM and SLA processes. In total, 260 printers were deployed to manufacture over 3,200 components, with approximately 23.5 m³ of printed volume and nearly 2.2 tons of polymer materials. The project required around 29,600 hours of 3D printing, supported by dedicated engineering and assembly activities

Technical overview

• Printing time: 29,600 hours of cumulative 3D printing
• Weight: 2 tons
• Dimensions: 16 m overall length, 12 m wingspan
• Post-Processing: Segment assembly on metal frame, surface finishing, sanding and coating, painting, interior installation (lighting, seating, flooring, cockpit simulation)

Setting a new standard for the mobility sector

The full-scale REGENT Viceroy Seaglider mockup demonstrates how robotic LFAM can redefine the production of complex mobility and industrial structures. Through the integration of Caracol’s Heron AM technology within Proto21’s additive manufacturing workflow, the project validates a scalable, tool-less manufacturing approach for large, custom parts.

Compared to conventional processes, LFAM enabled substantial efficiency gains, including up to 70% lead time reduction, 35% weight reduction, 65% waste reduction, and up to 45% cost savings, driven by optimized material deposition, reduced part count, and simplified assembly. For the mobility sector, the REGENT Viceroy Seaglider project represents a concrete step toward on-demand, large-scale production of highly customized structures, enabling faster development cycles and greater design freedom. The collaboration between Proto21 and Caracol, powered by Heron AM, demonstrates how advanced additive manufacturing ecosystems can effectively accelerate industrial innovation at scale.

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