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This paper aims to introduce a process chain spanning from scanned data to computer-aided engineering and further required simulations up to the subsequent production. This approach has the potential to reduce production costs and accelerate the procedure.

A parametric computer-aided design (CAD) model of the flyer wearing a wingsuit is created enabling easy changes in its posture and the wingsuit geometry. The objective is to track the influence of geometry changes in a timely manner for following simulation scenarios.

At the final stage, the two-dimensional (2D) pattern cuts were derived from the developed three-dimensional (3D) wingsuit, and the results were compared with the conventional ones used in the first stages of the wingsuit development.

Proposing a virtual development process chain is challenging; apart from the fact that the CAD construction of a wingsuit flyer – in itself posing a complicated task – is required at a very early stage of the procedure.