Project Iron Man · Hardware designation TRUDELL MK-I · Development program

Experimental
wearable engineering.

An Iron Man-inspired program exploring wearable systems, robotics, and potential powered flight. The hard part is not thrust; micro-turbines can lift a person today. The hard parts are control, because a body in flight needs six axes corrected faster than a human can, and physiology, because the human inside starts losing vision around 4 g. These pages lay out the problem honestly: concepts, design targets, prototypes and tested results, kept apart.

PROGRAM STATUS: CONCEPT AND DESIGN. No hardware has been built, hovered or flown. Figures on this page are design targets, published physiology, or component specifications from suppliers, and are labelled as such.
Design targets · not validated
2,750 NThrust, 5 turbines at supplier spec
160 kgAll-up weight budget incl. pilot
1.75Thrust-to-weight if both hold
8–12 minEndurance estimate on 20 kg fuel
≥ 500 HzInner control loop target
≤ 6 gProposed upright limit
4,500 mProposed unpressurised ceiling
N + 1Engine-out hover, design requirement
Interactive concept

Tap a component. See what it does and what controls it.

Each hardware component is paired with the control function the flight controller would own. The component list is a design concept; specifications are supplier data or targets, and each card says which.

CONCEPT MODEL

The 3D figure is a placeholder body model, not the MK-I design. Hotspots mark intended mounting locations.

First design requirement

Keep the pilot conscious.

G-induced loss of consciousness kills fighter pilots who have G-suits, training and a reclined seat. A standing pilot in a suit has none of that by default, so the design has to add all of it, plus a controller that unloads before a human could. No system can guarantee a pilot never blacks out. The goal is to make it as unlikely as engineering allows and survivable if it happens. The simulator below is a concept model of that logic, built on published physiology. It has not been validated against a real pilot or a real suit.

Concept simulator · sustained +Gz on the pilot
1.0 g
PILOT AUTHORITYModelled tolerance: 4.7 g
1 g4.5 caution6 warn7.5 override9 ceiling

Proposed intervention ladder · concept
PLANNEDG-suit: calves, thighs, abdomen inflate from ~3 g
PLANNEDEye-tracker: fixation loss and pupil lag trigger unload
PLANNEDAuto-recovery: level, 1 g, automated landing if unresponsive

Tolerance figures are conservative published ranges for a healthy, trained adult. Individual tolerance is lower when tired, dehydrated, hung over, sick or scared. Full physiology →

Simulators

Run the numbers

Toy models with stated constants. Good enough to argue with, not good enough to fly on, and not a substitute for the hardware-in-the-loop simulation planned in Phase 0.

✈ Flight physics

0km/h, prone cruise (model)
0m altitude (model)
1.00g on pilot (model)
0min endurance (estimate)
0 Nthrust
0 Ndrag
0 km/hV max
0T / W

⚡ Electrical budget ·

Proposed priority order: life support → flight computers → flight actuators → sensors → everything else. Numbers are a budget, not measurements.

🗺 Mission profile · what a first full sortie would look like

🛡 Damage model · concept

Why the suit needs an automated controller

Human pilot vs flight controller (design)

HumanController, as designed
Conscious decisions~5 per secondInner loop target ≥ 500 Hz
Reaction time200–300 msSensing in ms; actuation limited by gimbals (~40 ms) and engine spool (~3 s)
Axes controlled at once2, with training6 degrees of freedom + 5 engines (thrust allocation to be built)
Notices own blackoutNo. By definition.Design: eye-tracker, ECG, head accelerometer, control-input coherence
Flies while pilot is unconsciousNoDesign goal: level, hold 1 g, automated landing. Unbuilt.

Where HQ fits: Hylaq Quantum is local-first, on-device intelligence research. It is a candidate for the supervisory layer of this controller, never the inner loop, and nothing about it is a validated aircraft control system.

Proposed flight envelope · design targets

Limits the controller would enforce

Sustained G+6 g upright · +8 g prone · −2 g
Onset rate≤ 3 g/s commanded
Speed250 km/h (visor, windblast, bird-strike energy)
Altitude4,500 m unpressurised · O2 on above 3,000 m
Descent rate1.5 m/s below 20 m · 15 m/s emergency
Bird strike1 kg at 250 km/h = 2.4 kJ into the visor
Helmet COWarn 25 ppm · abort 50 ppm
Core temperatureWarn 38.5 °C · land 39.0 °C
FuelLand with 2 min reserve, always

Reality check, stated once so you can trust the rest. Jet suits fly today (Gravity Industries: five turbines, 5–10 minute flights, a 137 km/h record). What does not exist: a 150 kW pocket reactor, 20 minutes of electric hover, 210° AR visors, or armor that is simultaneously light, bulletproof and cheap. And nothing in this program has been built or flown. The MK-I pages separate shipping components, engineering we have to do, and targets that need a breakthrough, and every number is a target, a published figure, or a supplier spec until a test says otherwise.

Join the build

We need propulsion, controls, aerospace medicine and money.

Engineers who have run a gas turbine, control people who have tuned a real flight controller, a flight surgeon who has seen G-LOC in a centrifuge, and partners who want to fund Phase 0 and 1. Tell us which one you are.