Case Study: Gilo Industries achieves record 29,494 ft Everest paramotor flight with SolidWorks

How SOLIDWORKS Helped Bear Grylls Achieve the Impossible

Gilo Industries (Parajet) was hired to build a paramotor engine capable of flying Bear Grylls over Mount Everest — operating at roughly 9 km altitude in temperatures below −50°C and very high winds — a task that required an unprecedented power‑to‑weight ratio. To tackle this, Gilo Industries used SolidWorks 3D design and simulation tools, including FEA and dynamics/thermal analysis, to model, iterate and validate the extreme propulsion concept before physical prototyping.

Using SolidWorks, Gilo developed a 95 hp rotary engine with a dual‑fuel injector system, validated through simulation and testing, which enabled Bear Grylls to fly above Everest at 29,494 feet on 14 May 2007. SolidWorks’ tools cut testing costs, helped pare down weight, and later supported commercialization (Composer for assembly manuals and PDM Professional for AS9100 compliance), driving industry interest from Lockheed Martin, Boeing and NATO and the formation of Rotron to manufacture the engine.

Gilo Industries