Automated Patterning of Customized Extravehicular Activity (EVA) Spacesuit Pressure Garment Arm Assemblies

Creating safe, mobile, and comfortable extravehicular activity (EVA) spacesuit assemblies (SSA) is necessary for successful missions to low-Earth orbit and beyond. The 2020 NASA Technology Taxonomy TX06 identifies technology specific to keeping humans alive, safe, and comfortable in space. The need for advancement in the fit of spacesuits is described in TX06.2: Extravehicular Activity Systems which emphasizes NASA’s desire for launch, entry, and abort (LEA) “suit arm mobility via soft constant volume joints and enhanced patterning” . In the past there have been two primary methods used to achieve these goals: customization and standard sizes. During the Apollo program, suits were customized to fit to the astronauts. This helped with mobility but was not considered for the Space Shuttle Program. The shuttle program manufactured suits in standard sizes. This technique created mobility and sizing issues where smaller women were not able to fit into an Extravehicular Mobility Unit (EMU). NASA eventually only provided sizes medium, large, and extra-large for the shuttle EMUs, even though the original program in 1978 planned on five sizes. However, even if the astronaut was able to fit the length of their arms to a standard size suit arm, their elbow joint didn’t always align with the joint of the suit. Unaligned joints require astronauts to use more energy to perform tasks and can lead to discomfort and injury . This research goal is to create a system that can personalize patterns for SSA components using 3D scans and analytical modeling. The objectives are to design, prototype, and test a system that can personalize patterns for the SSA lower arm (with elbow) using automated landmarked dimensions. This multidisciplinary approach will include engineering and design principles from human integration, anthropometrics and ergonomics, and contact force analysis while also utilizing techniques used in the clothing manufacturing industry.

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