How AIRION, a Los Angeles-based startup, solved the critical issue of tactical dehydration in fighter pilots, particularly female pilots, through innovative design and rapid prototyping. They achieved this by winning an AFWERX challenge with their Advanced Inflight Relief Universal System (AIRUS), outcompeting larger defense contractors. The success of AIRION's "fly, fix, fly" approach was enabled by their in-house SLS 3D printers allowing for same-day iteration and testing with active pilots. This process ensured the device met sky-high requirements for comfort, durability, and biocompatibility, using TPU 90A Powder and Nylon 12 Powder for different components. Ultimately, bringing SLS production in-house transformed AIRION into a significant government contractor, addressing a longstanding problem for the US Armed Forces.