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NASA NTRS2011

Spacesuit Soft Upper Torso Sizing Systems

The passive sizing system consists of a series of low-profile pulleys attached to the front and back of the shoulder bearings on a spacesuit soft upper torso (SUT), textile cord or stainless steel cable, and a modified commercial ratchet mechanism. The cord/cable is routed through the pulleys and attached to the ratchet mechanism mounted on the front of the spacesuit within reach of the suited subject. Upon actuating the ratchet mechanism, the shoulder bearing breadth is changed, providing variable upper torso sizing. The active system consists of a series of pressurizable nastic cells embedded into the fabric layers of a spacesuit SUT. These cells are integrated to the front and back of the SUT and are connected to an air source with a variable regulator. When inflated, the nastic cells provide a change in the overall shoulder bearing breadth of the spacesuit and thus, torso sizing. The research focused on the development of a high-performance sizing and actuation system. This technology has application as a suit-sizing mechanism to allow easier suit entry and more accurate suit fit with fewer torso sizes than the existing EMU (Extravehicular Mobility Unit) suit system. This advanced SUT will support NASA s Advanced EMU Evolutionary Concept of a two-sizes-fit-all upper torso for replacement of the current EMU hard upper torso (HUT). Both the passive and nastic sizing system approaches provide astronauts with real-time upper torso sizing, which translates into a more comfortable suit, providing enhanced fit resulting in improved crewmember performance during extravehicular activity. These systems will also benefit NASA by reducing flight logistics as well as overall suit system cost. The nastic sizing system approach provides additional structural redundancy over existing SUT designs by embedding additional coated fabric and uncoated fabric layers. Two sizing systems were selected to build into a prototype SUT: one active and one passive. From manned testing, it was found that both systems offer good solutions to sizing a SUT to fit a crewmember. This new system provided improved suit don/doff over existing spacesuit designs as well as providing better fit at suit operational pressure resulting in improved comfort and mobility. It was found that a SUT with a sizing system may solve several problems that have plagued existing HUT designs, and that a SUT with a sizing system may be a viable option for advanced suit architectures.

Graziosi, David↗

NASA NTRS2016

Failure Simulation Testing of the Z-1 Spacesuit Titanium Bearing Assemblies

The Z-2 is a candidate for NASA's next generation spacesuit, designed for a range of possible missions with enhanced mobility for spacewalks both on planetary surfaces and in microgravity. Increased mobility was accomplished through innovations in shoulder and hip joints, using a number of new bearings to allow spacesuit wearers to dip, walk, and bend with ease; all important tasks for a planetary explorer collecting samples or traveling over rough terrain. The Advanced Spacesuit Development Team of NASA Johnson Space Center requested that the NASA White Sands Test Facility (WSTF) perform a series failure simulation tests on three titanium bearing assemblies, an elemental part of the joint construction used in new spacesuit designs. This testing simulated two undetected failures within the bearings and as a result the objective of this test program was to evaluate whether a failed or failing bearing could result in ignition of the titanium race material due to friction. The first failure was an inner seal leak sufficient to pressurize the race with +99 percent oxygen. The second failure was an improperly installed or mismatched ball port that created a protrusion in the ball bearing race, partially obstructing the nominal rolling path of each ball bearing. When the spacesuit bearings are assembled, bearing balls are loaded into the assembly via a ball port. The ball port is specific and unique to each bearing assembly (matched pair). The simulated mismatched ball port is a significant source of friction, which would be caused by an assembly error. To evaluate this risk, the bearings were cycled in a simulated worst-case scenario environment, with operational loads, and potential flaw conditions. During test the amount of actuation torque required and heat generated through continuous operation were measured and the bearings were observed for sparks or burning events. This paper provides detailed descriptions of the test hardware, methodology, and results.

de Baca, Richard C.↗

NASA NTRS2024

Effect of Varying HUT Sizing on Human-Spacesuit Contact Patterns

Fit, comfort, and mobility of the spacesuit rely on the location, magnitude, and type of contact between the suit and wearer. Typically, spacesuits include the Hard Upper Torso (HUT) comprising the upper torso of the spacesuit. Potential injuries from hard contact between the wearer’s shoulders and the HUT are a concern; therefore, to investigate spacesuit-wearer contact patterns, data from a retrospective study was analyzed. This study had eight subjects wearing the Shuttle Extravehicular Mobility Unit (EMU) spacesuit in two configurations, one with a nominally sized HUT and another with an oversized HUT. The subjects were sized per the NASA standard suit fit procedure. The suit’s arms and lower body were also resized to provide nominal arm and lower body fit, accounting for the larger HUT. Subjects held various shoulder postures (neutral posture, and various maximum shoulder rotations) with the suit pressurized to 4.3 PSI. For each posture, subjects reported the intensity of their perceived contact with the suit on a Borg CR10 scale, 0 indicating a non-existent contact intensity, and 10 representing a maximal contact intensity. Ratings were recorded for 11 regions covering the upper body and these ratings were used to determine the impact of body shape and size on suit contact. Our preliminary findings suggest that oversized HUTs had less contact regions than compared to the nominal HUT; and the region of contact, contact patterns, and contact intensities varied from person to person with the oversized HUT. This variance could be linked to subjects’ body shape and size. The next goal is to establish a causal factor between body shape and size, pose, contact region, and the HUT size. The outcome is expected to help understand the overall contact trends and insights into the influence of HUT sizing on suit fit.

Will Green↗

NASA NTRS2026

xEMU Spacesuit Boot Lunar South Pole Thermal Vacuum Testing

The Exploration Extravehicular Mobility Unit (xEMU) spacesuit lunar boot was evaluated in the Jet Propulsion Lab (JPL) CITADEL thermal vacuum chamber at lunar South Pole conditions. The JPL CITADEL chamber provides a radiation environment and contact plate temperature of 48K, simulating the temperature of a lunar Permanently Shadowed Region (PSR) at the South Pole of the Moon. The main objectives of the test series are: to evaluate the risk lunar PSRs pose to advanced spacesuit boots, validate the xEMU lunar boot thermal model, and to develop a test methodology to evaluate lunar spacesuit boots. To simulate the thermal effects of a crewmember’s foot inside the boot, a thermal manikin foot was developed to inject heat into the spacesuit boot. Thermal data was collected through a variety of sensors including thermocouples, thermistors, heat flux sensors, and infrared cameras. A test matrix was developed to investigate the variables of foot contact force, simulated skin temperature, external contact plate temperature, and ventilation flowrate. The JPL CITADEL chamber includes a loadlock (airlock) that afforded the ability to simulate the transition of the boot from a thermally neutral IVA condition to a cold EVA condition within seconds. This paper will document the test design, test objectives, success criteria, test support equipment, spacesuit boot to chamber interfaces, and configuration of the test article. Additionally, this paper will document the high-level results of the testing. More detailed test results will be presented in a different paper.

Ben Swartout↗

NASA NTRS2024

Transitioning Sixty Years of NASA Spacesuit Knowledge Capture Lessons Learned to Searchable Knowledge Transfer Databases

Sixty years of spacesuit knowledge capture and lessons learned by spacesuit subject matter experts are documented on videos and presentations and archived with the NASA Engineering and Safety Center (NESC) Academy. The NESC Academy is a web-based platform that hosts online courses by technical experts. A process is underway to transition these decades of lessons learned from the U.S. Spacesuit Knowledge Capture Program Library into more quicky searchable databases and to proactively provide this information to those working on spacesuit projects. Hundreds of lessons learned from Project Mercury, Gemini, Apollo, Apollo- Soyuz Test Project, Skylab, Space Shuttle, International Space Station, and Artemis have been captured in a format that can be quickly searched, enabling users to find information directly applicable to their needs. Transitioning this information to a NASA wiki page will further enhance search and retrieval of data immediately useful to users. This paper provides information about how the lessons learned were determined and how to access them.

spacesuit↗

NASA NTRSDate not supplied

Transitioning Sixty Years of NASA Spacesuit Knowledge Capture Lessons Learned to Searchable Knowledge Transfer Databases

spacesuit↗

NASA NTRS1991

Spacesuit guidebook

This guidebook is designed to supplement the Spacesuit wall chart (WAL-114) published by the Education Affairs Division, January 1990. The wall chart depicts Astronaut Bruce McCandless on his historic first untethered spacewalk using the manned maneuvering unit. He flew on Shuttle mission 41-B, and ventured 100 meters for the Shuttle's cargo bay and returned safely. This guidebook explains in depth the elements depicted on the wall chart in see-through and cut-away perspectives. Together the wall chart and guidebook show as well as explain the inside workings of the spacesuit and its various components. Forty separate elements are identified with an accompanying numerical legend. Those elements are further explained in this guidebook along with their functions and how they work in relation to other elements. Additional chapters discuss essential components of the spacesuit such as the primary life support system and the manned maneuvering unit, and the method for donning the spacesuit.

Source record↗

NASA NTRS2011

Spacesuit and Space Vehicle Comparative Ergonomic Evaluation

With the advent of the latest manned spaceflight objectives, a series of prototype launch and reentry spacesuit architectures were evaluated for eventual down selection by NASA based on the performance of a set of designated tasks. A consolidated approach was taken to testing, concurrently collecting suit mobility data, seat-suit-vehicle interface clearances and movement strategies within the volume of a Multi-Purpose Crew Vehicle mockup. To achieve the objectives of the test, a requirement was set forth to maintain high mockup fidelity while using advanced motion capture technologies. These seemingly mutually exclusive goals were accommodated with the construction of an optically transparent and fully adjustable frame mockup. The mockup was constructed such that it could be dimensionally validated rapidly with the motion capture system. This paper will describe the method used to create a motion capture compatible space vehicle mockup, the consolidated approach for evaluating spacesuits in action, as well as the various methods for generating hardware requirements for an entire population from the resulting complex data set using a limited number of test subjects. Kinematics, hardware clearance, suited anthropometry, and subjective feedback data were recorded on fifteen unsuited and five suited subjects. Unsuited subjects were selected chiefly by anthropometry, in an attempt to find subjects who fell within predefined criteria for medium male, large male and small female subjects. The suited subjects were selected as a subset of the unsuited subjects and tested in both unpressurized and pressurized conditions. Since the prototype spacesuits were fabricated in a single size to accommodate an approximately average sized male, the findings from the suit testing were systematically extrapolated to the extremes of the population to anticipate likely problem areas. This extrapolation was achieved by first performing population analysis through a comparison of suited subjects performance to their unsuited performance and then applying the results to the entire range of population. The use of a transparent space vehicle mockup enabled the collection of large amounts of data during human-in-the-loop testing. Mobility data revealed that most of the tested spacesuits had sufficient ranges of motion for tasks to be performed successfully. A failed tasked by a suited subject most often stemmed from a combination of poor field of view while seated and poor dexterity of the gloves when pressurized or from suit/vehicle interface issues. Seat ingress/egress testing showed that problems with anthropometric accommodation does not exclusively occur with the largest or smallest subjects, but rather specific combinations of measurements that lead to narrower seat ingress/egress clearance.

England, Scott↗

NASA NTRS2010

Chinese Spacesuit Analysis

In 2008, China became only the 3rd nation to perform an Extravehicular Activity (EVA) from a spacecraft. An overview of the Chinese spacesuit and life support system were assessed from video downlinks during their EVA; from those assessments, spacesuit characteristics were identified. The spacesuits were compared against the Russian Orlan Spacesuit and the U.S. Extravehicular Mobility Unit (EMU). China's plans for future missions also were presented.

Croog, Lewis↗

NASA NTRS2012

Comparative Ergonomic Evaluation of Spacesuit and Space Vehicle Design

With the advent of the latest human spaceflight objectives, a series of prototype architectures for a new launch and reentry spacesuit that would be suited to the new mission goals. Four prototype suits were evaluated to compare their performance and enable the selection of the preferred suit components and designs. A consolidated approach to testing was taken: concurrently collecting suit mobility data, seat-suit-vehicle interface clearances, and qualitative assessments of suit performance within the volume of a Multi-Purpose Crew Vehicle mockup. It was necessary to maintain high fidelity in a mockup and use advanced motion-capture technologies in order to achieve the objectives of the study. These seemingly mutually exclusive goals were accommodated with the construction of an optically transparent and fully adjustable frame mockup. The construction of the mockup was such that it could be dimensionally validated rapidly with the motioncapture system. This paper describes the method used to create a space vehicle mockup compatible with use of an optical motion-capture system, the consolidated approach for evaluating spacesuits in action, and a way to use the complex data set resulting from a limited number of test subjects to generate hardware requirements for an entire population. Kinematics, hardware clearance, anthropometry (suited and unsuited), and subjective feedback data were recorded on 15 unsuited and 5 suited subjects. Unsuited subjects were selected chiefly based on their anthropometry in an attempt to find subjects who fell within predefined criteria for medium male, large male, and small female subjects. The suited subjects were selected as a subset of the unsuited medium male subjects and were tested in both unpressurized and pressurized conditions. The prototype spacesuits were each fabricated in a single size to accommodate an approximately average-sized male, so select findings from the suit testing were systematically extrapolated to the extremes of the population to anticipate likely problem areas. This extrapolation was achieved by first comparing suited subjects performance with their unsuited performance, and then applying the results to the entire range of the population. The use of a transparent space vehicle mockup enabled the collection of large amounts of data during human-in-the-loop testing. Mobility data revealed that most of the tested spacesuits had sufficient ranges of motion for the selected tasks to be performed successfully. A suited subject's inability to perform a task most often stemmed from a combination of poor field of view in a seated position, poor dexterity of the pressurized gloves, or from suit/vehicle interface issues. Seat ingress and egress testing showed that problems with anthropometric accommodation did not exclusively occur with the largest or smallest subjects, but also with specific combinations of measurements that led to narrower seat ingress/egress clearance.

England, Scott↗

NASA NTRS2013

Hollow-Fiber Spacesuit Water Membrane Evaporator

The hollow-fiber spacesuit water membrane evaporator (HoFi SWME) is being developed to perform the thermal control function for advanced spacesuits and spacecraft to take advantage of recent advances in micropore membrane technology in providing a robust, heat-rejection device that is less sensitive to contamination than is the sublimator. After recent contamination tests, a commercial-off-the-shelf (COTS) micro porous hollow-fiber membrane was selected for prototype development as the most suitable candidate among commercial hollow-fiber evaporator alternatives. An innovative design that grouped the fiber layers into stacks, which were separated by small spaces and packaged into a cylindrical shape, was developed into a full-scale prototype for the spacesuit application. Vacuum chamber testing has been performed to characterize heat rejection as a function of inlet water temperature and water vapor back-pressure, and to show contamination resistance to the constituents expected to be found in potable water produced by the wastewater reclamation distillation processes. Other tests showed tolerance to freezing and suitability to reject heat in a Mars pressure environment. In summary, HoFi SWME is a lightweight, compact evaporator for heat rejection in the spacesuit that is robust, contamination- insensitive, freeze-tolerant, and able to reject the required heat of spacewalks in microgravity, lunar, and Martian environments. The HoFi is packaged to reject 810 W of heat through 800 hours of use in a vacuum environment, and 370 W in a Mars environment. The device also eliminates free gas and dissolved gas from the coolant loop.

Bue, Grant↗

NASA NTRS2014

Spacesuit Water Membrane Evaporator; An Enhanced Evaporative Cooling Systems for the Advanced Extravehicular Mobility Unit Portable Life Support System

Spacesuit Water Membrane Evaporator - Baseline heat rejection technology for the Portable Life Support System of the Advanced EMU center dot Replaces sublimator in the current EMU center dot Contamination insensitive center dot Can work with Lithium Chloride Absorber Radiator in Spacesuit Evaporator Absorber Radiator (SEAR) to reject heat and reuse evaporated water The Spacesuit Water Membrane Evaporator (SWME) is being developed to replace the sublimator for future generation spacesuits. Water in LCVG absorbs body heat while circulating center dot Warm water pumped through SWME center dot SWME evaporates water vapor, while maintaining liquid water - Cools water center dot Cooled water is then recirculated through LCVG. center dot LCVG water lost due to evaporation (cooling) is replaced from feedwater The Independent TCV Manifold reduces design complexity and manufacturing difficulty of the SWME End Cap. center dot The offset motor for the new BPV reduces the volume profile of the SWME by laying the motor flat on the End Cap alongside the TCV.

Bue, Grant C.↗

NASA NTRS2015

Non-Intrusive, Distributed Gas Sensing Technology for Advanced Spacesuits

Chemical sensors for monitoring gas composition, including oxygen, humidity, carbon dioxide, and trace contaminants, are needed to characterize and validate spacesuit design and operating parameters. This paper reports on the first prototypes of a non-intrusive gas sensing technology based on flexible sensitive patches positioned inside spacesuit prototypes and interrogated via optical fibers routed outside the suit, taking advantage of the transparent materials of the suit prototypes. The sensitive patches are based on luminescent materials whose emission parameters vary with the partial pressure of a specific gas. Patches sensitive to carbon dioxide, humidity, and temperature have been developed, and their preliminary laboratory characterization in Mark III-like helmet parts is described. The first prototype system consists of a four-channel fiber optic luminescent detector that can be used to monitor any of the selected target gases at four locations. To switch from one gas to another we replace the (disposable) sensor patches and adjust the system settings. Repeatability among sensitive patches and of sensor performance from location to location has been confirmed, assuring that suit engineers will have flexibility in selecting multiple sensing points, fitting the sensor elements into the spacesuit, and easily repositioning the sensor elements as desired. The evaluation of the first prototype for monitoring carbon dioxide during washout studies in a spacesuit prototype is presented.

Delgado, Jesus↗

NASA NTRS2016

U.S. Spacesuit Knowledge Capture Accomplishments in Fiscal Year 2015

The NASA U.S. Spacesuit Knowledge Capture (SKC) Program continues to capture, share, and archive significant spacesuit-related knowledge with engineers and other technical staff and invested entities. Since its 2007 inception, the SKC Program has hosted and recorded more than 65 events. By the end of Fiscal Year (FY) 2015, 40 of these were processed and uploaded to a publically accessible NASA Web site where viewers can expand their knowledge about the spacesuit's evolution, known capability and limitations, and lessons learned. Sharing this knowledge with entities beyond NASA can increase not only more people's understanding of the technical effort and importance involved in designing a spacesuit, it can also expand the interest and support in this valuable program that ensures significant knowledge is retained and accessible. This paper discusses the FY 2015 SKC events, the release and accessibility of the approved events, and the program's future plans.

Chullen, Cinda↗

NASA NTRS2016

U.S. Spacesuit Knowledge Capture Accomplishments in Fiscal Year 2015

The NASA U.S. Spacesuit Knowledge Capture (SKC) Program continues to capture, share, and archive significant spacesuit-related knowledge with engineers and other technical staff and invested entities. Since its 2007 inception, the SKC Program has hosted and recorded more than 75 events. By the end of Fiscal Year (FY) 2015, 40 of these were processed and uploaded to a publically accessible NASA Web site where viewers can expand their knowledge about the spacesuit's evolution, known capabilities and limitations, and lessons learned. Sharing this knowledge with entities beyond NASA can increase not only more people's understanding of the technical effort and importance involved in designing a spacesuit, it can also expand the interest and support in this valuable program that ensures significant knowledge is retained and accessible. This paper discusses the FY 2015 SKC events, the release and accessibility of the approved events, and the program's future plans.

Chullen, Cinda↗

NASA NTRS2018

Low-Power, Chip-Scale, Carbon Dioxide Gas Sensors for Spacesuit Monitoring

N5 Sensors, Inc. through a Small Business Technology Transfer (STTR) contract award has been developing ultra-small, low-power carbon dioxide (CO2) gas sensors, suited for monitoring CO2 levels inside NASA spacesuits. Due to the unique environmental conditions within the spacesuits, such as high humidity, large temperature swings, and operating pressure swings, measurement of key gases relevant to astronaut's safety and health such as(CO2), is quite challenging. Conventional non-dispersive infrared absorption based CO2 sensors present challenges inside the spacesuits due to size, weight, and power constraints, along with the ability to sense CO2 in a high humidity environment. Unique chip-scale, nanoengineered chemiresistive gas-sensing architecture has been developed for this application, which can be operated in a typical space-suite environmental conditions. Unique design combining the selective adsorption properties of the nanophotocatalytic clusters of metal-oxides and metals, provides selective detection of CO2 in high relative humidity conditions. All electronic design provides a compact and low-power solution, which can be implemented for multipoint detection of CO2 inside the spacesuits. This paper will describe the sensor architecture, development of new photocatalytic material for better sensor response, and advanced structure for better sensitivity and shorter response times.

Rani, Asha↗

NASA NTRS2018

The History & Evolution of Spacesuits and Spacewalks - Walking in Space

The presentation and videos that will be included in this technology talk will summarize the basic functions of spacesuits, the evolution of spacesuit design, and the development plans for future exploration spacesuits. The videos will run in a loop with no audio. The speakers will generally follow the slide presentation. There will be a 5-minute intro on basic suit functions, followed by a 7-10 minute discussion on suit history and evolution, then 7-10 minutes to cover the current ISS (International Space Station) suit and the development of the next generation exploration spacesuits. That will leave around 5-10 minutes for questions and answers.

Hughes, David↗

NASA NTRS2018

Low-Power, Chip-Scale, CO2 Gas Sensors for Spacesuit Monitoring

N5 Sensors, Inc. and NASA through a STTR program are jointly developing ultra-small, low-power carbon dioxide (CO2) gas sensors, suited for monitoring CO2 levels inside the spacesuits. Due to the unique environmental conditions within the spacesuits, such as high humidity, large temperature and operating pressure swings, measurement of key gases relevant to astronaut's safety and health such as carbon dioxide, is quite challenging. Conventional non-dispersive infrared absorption based CO2 sensors cannot be effectively implemented inside the spacesuits due to their sizes, weights, and power constraints. Metal-oxide based sensors have been effectively miniaturized for several applications, however detection of CO2 utilizing metal-oxide based sensors is challenging due to the chemical inertness and high stability of CO2 at room-temperatures. To mitigate these limitations, unique chip-scale, nanoengineered chemiresistive gas-sensing architecture has been developed - to allow the Metal-oxide sensors to operate in space-suite environmental conditions. Unique design combining the selective adsorption properties of the nanophotocatalytic clusters of metal-oxides and metals, provides selective detection of CO2 in high relative humidity conditions. All electronic design provides a compact and low-power solution, which can be implemented for multipoint detection of CO2 inside the spacesuits. This paper will describe a novel approach in refining the sensor architecture, development of new photocatalytic material for better sensor performance.

Thomson, Brian↗