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Space suit
Space suit
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Apollo spacesuit worn by astronaut Buzz Aldrin on Apollo 11
Orlan space suit worn by astronaut Michael Fincke outside the International Space Station
Feitian space suit being displayed at the National Museum of China

A space suit (or spacesuit) is an environmental suit used for protection from the harsh environment of outer space, mainly from its vacuum as a highly specialized pressure suit, but also its temperature extremes, as well as radiation and micrometeoroids. Basic space suits are worn as a safety precaution inside spacecrafts in case of loss of cabin pressure. For extravehicular activity (EVA) more complex space suits are worn, featuring a portable life support system.

Pressure suits are in general needed at low pressure environments above the Armstrong limit, at around 19,000 m (62,000 ft) above Earth. Space suits augment pressure suits with complex system of equipment and environmental systems designed to keep the wearer comfortable, and to minimize the effort required to bend the limbs, resisting a soft pressure garment's natural tendency to stiffen against the vacuum. A self-contained oxygen supply and environmental control system is frequently employed to allow complete freedom of movement, independent of the spacecraft.

Three types of space suits exist for different purposes: IVA (intravehicular activity), EVA (extravehicular activity), and IEVA (intra/extravehicular activity). IVA suits are meant to be worn inside a pressurized spacecraft, and are therefore lighter and more comfortable. IEVA suits are meant for use inside and outside the spacecraft, such as the Gemini G4C suit. They include more protection from the harsh conditions of space, such as protection from micrometeoroids and extreme temperature change. EVA suits, such as the EMU, are used outside spacecraft, for either planetary exploration or spacewalks. They must protect the wearer against all conditions of space, as well as provide mobility and functionality.[1]

The first full-pressure suits for use at extreme altitudes were designed by individual inventors as early as the 1930s. The first space suit worn by a human in space was the Soviet SK-1 suit worn by Yuri Gagarin in 1961. Since then space suits have been worn beside in Earth orbit, en-route and on the surface of the Moon.

Requirements

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Space suits being used to work on the International Space Station.

A space suit must perform several functions to allow its occupant to work safely and comfortably, inside or outside a spacecraft. It must provide:

  • A stable internal pressure. This can be less than Earth's atmosphere, as there is usually no need for the space suit to carry nitrogen (which comprises about 78% of Earth's atmosphere and is not used by the body). Lower pressure allows for greater mobility, but requires the suit occupant to breathe pure oxygen for a time before going into this lower pressure, to avoid decompression sickness.
  • Mobility. Movement is typically opposed by the pressure of the suit; mobility is achieved by careful joint design. See the Design concepts section.
  • Supply of breathable oxygen and elimination of carbon dioxide; these gases are exchanged with the spacecraft or a Portable Life Support System (PLSS)
  • Temperature regulation. Unlike on Earth, where heat can be transferred by convection to the atmosphere, in space, heat can be lost only by thermal radiation or by conduction to objects in physical contact with the exterior of the suit. Since the temperature on the outside of the suit varies greatly between sunlight and shadow, the suit is heavily insulated, and air temperature is maintained at a comfortable level.
  • A communication system, with external electrical connection to the spacecraft or PLSS
  • Means of collecting and containing solid and liquid bodily waste (such as a Maximum Absorbency Garment)

Secondary requirements

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AstroRad developed by Israeli StemRad anti Radiation spacesuit
From left to right, Margaret R. (Rhea) Seddon, Kathryn D. Sullivan, Judith A. Resnick, Sally K. Ride, Anna L. Fisher, and Shannon W. Lucid—The first six female astronauts of the United States stand with a Personal Rescue Enclosure, a spherical life support ball for emergency transfer of people in space

Advanced suits better regulate the astronaut's temperature with a Liquid Cooling and Ventilation Garment (LCVG) in contact with the astronaut's skin, from which the heat is dumped into space through an external radiator in the PLSS.

Additional requirements for EVA include:

Layers of a space suit

As part of astronautical hygiene control (i.e., protecting astronauts from extremes of temperature, radiation, etc.), a space suit is essential for extravehicular activity. The Apollo/Skylab A7L suit included eleven layers in all: an inner liner, a LCVG, a pressure bladder, a restraint layer, another liner, and a Thermal Micrometeoroid Garment consisting of five aluminized insulation layers and an external layer of white Ortho-Fabric. This space suit is capable of protecting the astronaut from temperatures ranging from −156 °C (−249 °F) to 121 °C (250 °F).[2]

During exploration of the Moon or Mars, there will be the potential for lunar or Martian dust to be retained on the space suit. When the space suit is removed on return to the spacecraft, there will be the potential for the dust to contaminate surfaces and increase the risks of inhalation and skin exposure. Astronautical hygienists are testing materials with reduced dust retention times and the potential to control the dust exposure risks during planetary exploration. Novel ingress and egress approaches, such as suitports, are being explored as well.

In NASA space suits, communications are provided via a cap worn over the head, which includes earphones and a microphone. Due to the coloration of the version used for Apollo and Skylab, which resembled the coloration of the comic strip character Snoopy, these caps became known as "Snoopy caps".

Operating pressure

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Astronaut Steven G. MacLean pre-breathes prior to an EVA

Generally, to supply enough oxygen for respiration, a space suit using pure oxygen must have a pressure of about 32.4 kPa (240 Torr; 4.7 psi), equal to the 20.7 kPa (160 Torr; 3.0 psi) partial pressure of oxygen in the Earth's atmosphere at sea level, plus 5.3 kPa (40 Torr; 0.77 psi) CO2[citation needed] and 6.3 kPa (47 Torr; 0.91 psi) water vapor pressure, both of which must be subtracted from the alveolar pressure to get alveolar oxygen partial pressure in 100% oxygen atmospheres, by the alveolar gas equation.[3] The latter two figures add to 11.6 kPa (87 Torr; 1.7 psi), which is why many modern space suits do not use 20.7 kPa (160 Torr; 3.0 psi), but 32.4 kPa (240 Torr; 4.7 psi) (this is a slight overcorrection, as alveolar partial pressures at sea level are slightly less than the former). In space suits that use 20.7 kPa, the astronaut gets only 20.7 kPa − 11.6 kPa = 9.1 kPa (68 Torr; 1.3 psi) of oxygen, which is about the alveolar oxygen partial pressure attained at an altitude of 1,860 m (6,100 ft) above sea level. This is about 42% of normal partial pressure of oxygen at sea level, about the same as pressure in a commercial passenger jet aircraft, and is the realistic lower limit for safe ordinary space suit pressurization which allows reasonable capacity for work.

Oxygen prebreathing

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When space suits below a specific operating pressure are used from craft that are pressurized to normal atmospheric pressure (such as the Space Shuttle), this requires astronauts to "pre-breathe" (meaning pre-breathe pure oxygen for a period) before donning their suits and depressurizing in the air lock. This procedure purges the body of dissolved nitrogen, so as to avoid decompression sickness due to rapid depressurization from a nitrogen-containing atmosphere.[1]

In the US space shuttle, cabin pressure was reduced from normal atmospheric to 70kPa (equivalent to an altitude of about 3000m) for 24 hours before EVA, and after donning the suit, a pre-breathing period of 45 minutes on pure oxygen before decompressing to the EMU working pressure of 30kPa. In the ISS there is no cabin pressure reduction, instead a 4-hour oxygen pre-breathe at normal cabin pressure is used to desaturate nitrogen to an acceptable level. US studies show that a rapid decompression from 101kPa to 55kPa has an acceptable risk, and Russian studies show that direct decompression from 101kPa to 40kPa after 30 minutes of oxygen pre-breathing, roughly the time required for pre-EVA suit checks, is acceptable.[1]

Physiological effects of unprotected space exposure

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The human body can briefly survive the hard vacuum of space unprotected,[4] despite contrary depictions in some popular science fiction. Consciousness is retained for up to 15 seconds as the effects of oxygen starvation set in. No snap freeze effect occurs because all heat must be lost through thermal radiation or the evaporation of liquids, and the blood does not boil because it remains pressurized within the body, but human flesh expands up to about twice its volume due to ebullism in such conditions, giving the visual effect of a body builder rather than an overfilled balloon.[5]

In space, there are highly energized subatomic particles that can cause radiation damage by disrupting essential biological processes. Exposure to radiation can create problems via two methods: the particles can react with water in the human body to produce free radicals that break DNA molecules apart, or by directly breaking the DNA molecules.[1][6]

Temperature in space can vary extremely depending on the exposure to radiant energy sources. Temperatures from solar radiation can reach up to 250 °F (121 °C), and in its absence, down to −387 °F (−233 °C). Because of this, space suits must provide sufficient insulation and cooling for the conditions in which they will be used.[1]

The vacuum environment of space has no pressure, so gases will expand and exposed liquids may evaporate. Some solids may sublimate. It is necessary to wear a suit that provides sufficient internal body pressure in space.[1][7] The most immediate hazard is in attempting to hold one's breath during explosive decompression as the expansion of gas can damage the lungs by overexpansion rupture. These effects have been confirmed through various accidents (including in very-high-altitude conditions, outer space and training vacuum chambers).[4][8] Human skin does not need to be protected from vacuum and is gas-tight by itself.[5] It only needs to be mechanically restrained to retain its normal shape and the internal tissues to retain their volume. This can be accomplished with a tight-fitting elastic body suit and a helmet for containing breathing gases, known as a space activity suit (SAS).[clarification needed][citation needed]

Design concepts

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NASA's Extravehicular Mobility Unit Vitruvian Spaceman patch (Space Shuttle version, with three stars representing NASA's human spaceflight programs)

A space suit should allow its user natural unencumbered movement. Nearly all designs try to maintain a constant volume no matter what movements the wearer makes. This is because mechanical work is needed to change the volume of a constant pressure system. If flexing a joint reduces the volume of the space suit, then the astronaut must do extra work every time they bend that joint, and they have to maintain a force to keep the joint bent. Even if this force is very small, it can be seriously fatiguing to constantly fight against one's suit. It also makes delicate movements very difficult. The work required to bend a joint is dictated by the formula

where Vi and Vf are respectively the initial and final volume of the joint, P is the pressure in the suit, and W is the resultant work. It is generally true that all suits are more mobile at lower pressures. However, because a minimum internal pressure is dictated by life support requirements, the only means of further reducing work is to minimize the change in volume.

All space suit designs try to minimize or eliminate this problem. The most common solution is to form the suit out of multiple layers. The bladder layer is a rubbery, airtight layer much like a balloon. The restraint layer goes outside the bladder, and provides a specific shape for the suit. Since the bladder layer is larger than the restraint layer, the restraint takes all of the stresses caused by the pressure inside the suit. Since the bladder is not under pressure, it will not "pop" like a balloon, even if punctured. The restraint layer is shaped in such a way that bending a joint causes pockets of fabric, called "gores", to open up on the outside of the joint, while folds called "convolutes" fold up on the inside of the joint. The gores make up for the volume lost on the inside of the joint, and keep the suit at a nearly constant volume. However, once the gores are opened all the way, the joint cannot be bent any further without a considerable amount of work.

In some Russian space suits, strips of cloth were wrapped tightly around the cosmonaut's arms and legs outside the space suit to stop the space suit from ballooning when in space.[citation needed]

The outermost layer of a space suit, the Thermal Micrometeoroid Garment, provides thermal insulation, protection from micrometeoroids, and shielding from harmful solar radiation.

There are four main conceptual approaches to suit design:

Soft suits

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Soft suits typically are made mostly of fabrics. All soft suits have some hard parts; some even have hard joint bearings. Intra-vehicular activity and early EVA suits were soft suits.[citation needed]

Hard-shell suits

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NASA's experimental AX-5 hard-shell space suit (1988)

Hard-shell suits are usually made of metal or composite materials and do not use fabric for joints. Hard suits joints use ball bearings and wedge-ring segments similar to an adjustable elbow of a stove pipe to allow a wide range of movement with the arms and legs. The joints maintain a constant volume of air internally and do not have any counter-force. Therefore, the astronaut does not need to exert to hold the suit in any position. Hard suits can also operate at higher pressures which would eliminate the need for an astronaut to pre-breathe oxygen to use a 34 kPa (4.9 psi) space suit before an EVA from a 101 kPa (14.6 psi) spacecraft cabin. The joints may get into a restricted or locked position requiring the astronaut to manipulate or program the joint.[clarification needed] The NASA Ames Research Center experimental AX-5 hard-shell space suit had a flexibility rating of 95%. The wearer could move into 95% of the positions they could without the suit on.[citation needed]

Hybrid suits

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Hybrid suits have hard-shell parts and fabric parts. NASA's Extravehicular Mobility Unit (EMU) uses a fiberglass Hard Upper Torso (HUT) and fabric limbs.[citation needed] ILC Dover's I-Suit replaces the HUT with a fabric soft upper torso to save weight, restricting the use of hard components to the joint bearings, helmet, waist seal, and rear entry hatch.[citation needed] Virtually all workable space suit designs incorporate hard components, particularly at interfaces such as the waist seal, bearings, and in the case of rear-entry suits, the back hatch, where all-soft alternatives are not viable.

Skintight suits

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Skintight suits, also known as mechanical counterpressure suits or space activity suits, are a proposed design which would use a heavy elastic body stocking to compress the body. The head is in a pressurized helmet, but the rest of the body is pressurized only by the elastic effect of the suit. This mitigates the constant volume problem,[citation needed] reduces the possibility of a space suit depressurization and gives a very lightweight suit. When not worn, the elastic garments may appear to be that of clothing for a small child. These suits may be very difficult to put on and face problems with providing a uniform pressure. Most proposals use the body's natural perspiration to keep cool. Sweat evaporates readily in vacuum and may desublime or deposit on objects nearby: optics, sensors, the astronaut's visor, and other surfaces. The icy film and sweat residue may contaminate sensitive surfaces and affect optical performance.

Contributing technologies

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Related preceding technologies include the stratonautical space suit, the gas mask used in World War II, the oxygen mask used by pilots of high-flying bombers in World War II, the high-altitude or vacuum suit required by pilots of the Lockheed U-2 and SR-71 Blackbird, the diving suit, rebreather, scuba diving gear, and many others.

Many space suit designs are taken from the U.S. Air Force suits, which are designed to work in "high-altitude aircraft pressure[s]",[1] such as the Mercury IVA suit or the Gemini G4C, or the Advanced Crew Escape Suits.[9]

Glove technology

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The Mercury IVA, the first U.S. space suit design, included lights at the tips of the gloves in order to provide visual aid. As the need for extravehicular activity grew, suits such as the Apollo A7L included gloves made of a metal fabric called Chromel-r in order to prevent punctures. In order to retain a better sense of touch for the astronauts, the fingertips of the gloves were made of silicone. With the shuttle program, it became necessary to be able to operate spacecraft modules, so the ACES suits featured gripping on the gloves. EMU gloves, which are used for spacewalks, are heated to keep the astronaut's hands warm. The Phase VI gloves, meant for use with the Mark III suit, are the first gloves to be designed with "laser scanning technology, 3D computer modeling, stereo lithography, laser cutting technology and CNC machining".[NASA, ILC Dover Inc. 1] This allows for cheaper, more accurate production, as well as increased detail in joint mobility and flexibility.

Life support technology

[edit]

Prior to the Apollo missions, life support in space suits was connected to the space capsule via an umbilical cable. However, with the Apollo missions, life support was configured into a removable capsule called the Portable Life Support System that allowed the astronaut to explore the Moon without having to be attached to the space craft. The EMU space suit, used for spacewalks, allows the astronaut to manually control the internal environment of the suit. The Mark III suit has a backpack containing about 12 pounds of liquid air for breathing, pressurization, and heat exchange.[clarification needed][9]

Helmet technology

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The development of the spheroidal dome helmet was key in balancing the need for field of view, pressure compensation, and low weight. One inconvenience with some space suits is the head being fixed facing forwards and being unable to turn to look sideways. Astronauts call this effect "alligator head".[citation needed]

High-altitude suits

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Pressurised suit prototype designed by military engineer Emilio Herrera for a stratospheric balloon flight. c. 1935
  • Evgeniy Chertovsky created his full-pressure suit or high-altitude "skafandr" (скафандр) in 1931.[10] (скафандр also means "diving suit").[11]
  • Emilio Herrera designed and built a full-pressure "stratonautical space suit" in 1935, which was to have been used during an open-basket balloon stratospheric flight scheduled for early 1936.[12]
  • In 1938 the Italian Air Force developed a high-altitude, semi-rigid pressurized suit, the first to be successfully used in operational conditions on October 22, 1938, by Lt.Col. Mario Pezzi during his first high-altitude record flight.[13]
  • Wiley Post experimented with a number of pressure suits for record-breaking flights.[14][15]
  • Russell Colley created the space suits worn by the Project Mercury astronauts, including fitting Alan Shepard for his ride as America's first man in space on May 5, 1961.[citation needed]

List of space suit models

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Soviet and Russian suit models

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United States suit models

[edit]
  • In the early 1950s, Siegfried Hansen and colleagues at Litton Industries designed and built a working hard-shell suit, which was used inside vacuum chambers and was the predecessor of space suits used in NASA missions.[16]
  • Navy Mark IV high-altitude/vacuum suit – used for Project Mercury (1961–1963).
  • Gemini space suits (1965–1966) – there were three main variants developed: G3C designed for intra-vehicle use; G4C specially designed for EVA and intra-vehicle use; and a special G5C spacesuit worn by the Gemini 7 crew for 14 days inside the spacecraft.
  • Manned Orbiting Laboratory MH-7 space suits for the canceled MOL program.
  • Apollo Block I A1C suit (1966–1967) – a derivative of the Gemini suit, worn by primary and backup crews in training for two early Apollo missions. The nylon pressure garment melted and burned through in the Apollo 1 cabin fire. This suit became obsolete when crewed Block I Apollo flights were discontinued after the fire.
  • Apollo/Skylab A7L EVA and Moon suits – The Block II Apollo suit was the primary pressure suit worn for eleven Apollo flights, three Skylab flights, and the US astronauts on the Apollo–Soyuz Test Project between 1968 and 1975. The pressure garment's nylon outer layer was replaced with fireproof Beta cloth after the Apollo 1 fire. This suit was the first to employ a liquid-cooled inner garment and outer micrometeoroid garment. Beginning with the Apollo 13 mission, it also introduced "commander's stripes" so that a pair of space walkers will not appear identical on camera.[17]
  • Shuttle Ejection Escape Suit – used from STS-1 (1981) to STS-4 (1982) by a two-man crew used in conjunction with the then-installed ejection seats. Derived from a USAF model.[18] These were removed once the Shuttle became certified.
  • From STS-5 (1982) to STS-51-L (1986) no pressure suits were worn during launch and reentry. The crew would wear only a blue-flight suit with an oxygen helmet.
  • Launch Entry Suit first used on STS-26 (1988), the first flight after the Challenger disaster. It was a partial pressure suit derived from a USAF model.[19] It was used from 1988 to 1998.
  • Advanced Crew Escape Suit used on the Space Shuttle starting in 1994.[20] The Advanced Crew Escape Suit or ACES suit, is a full-pressure suit worn by all Space Shuttle crews for the ascent and entry portions of flight. The suit is a direct descendant of the United States Air Force high-altitude pressure suits worn by SR-71 Blackbird and U-2 spy plane pilots, North American X-15 and Gemini pilot-astronauts, and the Launch Entry Suits worn by NASA astronauts starting on the STS-26 flight. It is derived from a USAF model.
  • Extravehicular Mobility Unit (EMU) – used on both the Space Shuttle and International Space Station (ISS). The EMU is an independent anthropomorphic system that provides environmental protection, mobility, life support, and communications for a Space Shuttle or ISS crew member to perform an EVA in Earth orbit. Used from 1982 to present, but only available in limited sizing as of 2019.[21]
  • Aerospace company SpaceX developed an IVA suit which is worn by astronauts involved in Commercial Crew Program missions operated by SpaceX since the Demo-2 mission. As a continuation of this suit design, SpaceX developed an EVA suit in 2024. The EVA version of the suit was used during the Polaris Dawn private space mission for the first ever commercial spacewalk.[22]
  • Orion Crew Survival System (OCSS) – will be used during launch and re-entry on the Orion MPCV. It is derived from the Advanced Crew Escape Suit but is able to operate at a higher pressure and has improved mobility in the shoulders.[23]

SpaceX suit ("Starman suit")

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In February 2015, SpaceX began developing a space suit for astronauts to wear within the Dragon 2 space capsule.[24] Its appearance was jointly designed by Jose Fernandez—a Hollywood costume designer known for his works for superhero and science fiction films—and SpaceX founder and CEO Elon Musk.[25][26] The first images of the suit were revealed in September 2017.[27] A mannequin, called "Starman" (after David Bowie's song of the same name), wore the SpaceX space suit during the maiden launch of the Falcon Heavy in February 2018.[28][29] For this exhibition launch, the suit was not pressurized and carried no sensors.[30]

The suit, which is suitable for vacuum, offers protection against cabin depressurization through a single tether at the astronaut's thigh that feeds air and electronic connections. The helmets, which are 3D-printed, contain microphones and speakers. As the suits need the tether connection and do not offer protection against radiation, they are not used for extra-vehicular activities. The suits are custom-made for each astronaut.[31]

In 2018, NASA commercial crew astronauts Bob Behnken, and Doug Hurley tested the spacesuit inside the Dragon 2 spacecraft in order to familiarize themselves with the suit.[32] They wore it in the Crew Dragon Demo-2 flight launched on 30 May 2020.[29] The suit is worn by astronauts involved in Commercial Crew Program missions involving SpaceX.

On 4 May 2024, SpaceX unveiled a spacesuit designed for extravehicular activity based on the IVA suit for Polaris Dawn mission in Polaris program. As with the IVA suit, the helmets are 3D-printed, though the EVA helmet incorporates a heads-up display providing information and a camera on suit metrics during operation. It is more mobile, includes new thermal insulation fabrics, and materials used Falcon’s interstage and Crew Dragon’s external unpressurized trunk.[33]

Future NASA contracted suits

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On 1 June 2022, NASA announced it had selected competing Axiom Space and Collins Aerospace to develop and provide astronauts with next generation spacesuit and spacewalk systems to first test and later use outside the International Space Station, as well as on the lunar surface for the crewed Artemis missions, and prepare for human missions to Mars.[34][35][36]

Chinese suit models

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  • Shuguang (曙光, meaning "Dawn") space suit : First generation EVA space suit developed by China for the 1967 canceled Project 714 crewed space program. It has a mass of about 10 kilograms (20 lb), has an orange colour, and is made of high-resistance multi-layer polyester fabric. The astronaut could use it inside the cabin and conduct an EVA as well.[37][38][39]
  • 'Project 863 space suit: Cancelled project of second generation Chinese EVA space suit.[40]
  • Shenzhou IVA (神舟, meaning "Divine Vessel") space suit: The suit was first worn by Yang Liwei on Shenzhou 5, the first crewed Chinese space flight, it closely resembles a Sokol-KV2 suit, but it is believed to be a Chinese-made version rather than an actual Russian suit.[41][42] Pictures show that the suits on Shenzhou 6 differ in detail from the earlier suit; they are also reported to be lighter.[43]
  • Haiying (海鹰, meaning "Sea Hawk") EVA space suit: The imported Russian Orlan-M EVA suit is called Haiying. Used on Shenzhou 7.
  • Feitian (飞天, meaning "Sky Flyer") EVA space suit: Indigenously developed Chinese-made EVA space suit also used for the Shenzhou 7 mission.[44] The suit was designed for a spacewalk mission of up to seven hours.[45] Chinese astronauts have been training in the out-of-capsule space suits since July 2007, and movements are seriously restricted in the suits, with a mass of more than 110 kilograms (240 lb) each.[46] A new generation of Feitian space suit has been used since 2021 as the construction of Tiangong Space Station began.

Emerging technologies

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Several companies and universities are developing technologies and prototypes which represent improvements over current space suits.

Additive manufacturing

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3D printing (additive manufacturing) can be used to reduce the mass of hard-shell space suits while retaining the high mobility they provide. This fabrication method also allows for the potential for in-suit fabrication and repair of suits, a capability which is not currently available, but will likely be necessary for Martian exploration.[47] The University of Maryland began development of a prototype 3D printed hard suit in 2016, based on the kinematics of the AX-5. The prototype arm segment is designed to be evaluated in the Space Systems Laboratory glovebox to compare mobility to traditional soft suits. Initial research has focused on the feasibility of printing rigid suit elements, bearing races, ball bearings, seals, and sealing surfaces.[48]

Astronaut Glove Challenge

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There are certain difficulties in designing a dexterous space suit glove and there are limitations to the current designs. For this reason, the Centennial Astronaut Glove Challenge was created to build a better glove. Competitions have been held in 2007 and 2009, and another is planned. The 2009 contest required the glove to be covered with a micro-meteorite layer.

Aouda.X

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Aouda.X

Since 2009, the Austrian Space Forum has been developing "Aouda.X", an experimental Mars analogue space suit focusing on an advanced human–machine interface and on-board computing network to increase situational awareness. The suit is designed to study contamination vectors in planetary exploration analogue environments and create limitations depending on the pressure regime chosen for a simulation.

Since 2012, for the Mars2013 analogue mission by the Austrian Space Forum to Erfoud, Morocco, the Aouda.X analogue space suit has a sister in the form of Aouda.S.[49] This is a slightly less sophisticated suit meant primarily to assist Aouda.X operations and be able to study the interactions between two (analogue) astronauts in similar suits.

The Aouda.X and Aouda.S space suits have been named after the fictional princess from the Jules Verne's 1873 novel Around the World in Eighty Days. A public display mock-up of Aouda.X (called Aouda.D) is currently on display at the Dachstein Ice Cave in Obertraun, Austria, after the experiments done there in 2012.[50]

Axiom Space and Prada

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In 2024, at the International Astronautical Congress in Milan, Italy, Axiom Space and Prada showed the results of an ongoing collaboration to develop a spacesuit for NASA's Artemis III mission.[36]

Bio-Suit

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Bio-Suit is a space activity suit under development at the Massachusetts Institute of Technology, which as of 2006 consisted of several lower leg prototypes. Bio-suit is custom fit to each wearer, using laser body scanning.[needs update]

Constellation Space Suit system

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On August 2, 2006, NASA indicated plans to issue a Request for Proposal (RFP) for the design, development, certification, production, and sustaining engineering of the Constellation Space Suit to meet the needs of the Constellation Program.[51] NASA foresaw a single suit capable of supporting: survivability during launch, entry and abort; zero-gravity EVA; lunar surface EVA; and Mars surface EVA.

On June 11, 2008, NASA awarded a US$745 million contract to Oceaneering International to create the new space suit.[52]

Final Frontier Design IVA Space Suit

[edit]
Final Frontier Design IVA Space Suit

Final Frontier Design (FFD) is developing a commercial full IVA space suit, with their first suit completed in 2010.[53] FFD's suits are intended as a light-weight, highly mobile, and inexpensive commercial space suits. Since 2011, FFD has upgraded IVA suit's designs, hardware, processes, and capabilities. FFD has built a total of 7 IVA space suit (2016) assemblies for various institutions and customers since founding, and has conducted high fidelity human testing in simulators, aircraft, microgravity, and hypobaric chambers. FFD has a Space Act Agreement with NASA's Commercial Space Capabilities Office to develop and execute a Human Rating Plan for FFD IVA suit.[54] FFD categorizes their IVA suits according to their mission: Terra for Earth-based testing, Stratos for high altitude flights, and Exos for orbital space flights. Each suit category has different requirements for manufacturing controls, validations, and materials, but are of a similar architecture.

I-Suit

[edit]

The I-Suit is a space suit prototype also constructed by ILC Dover, which incorporates several design improvements over the EMU, including a weight-saving soft upper torso. Both the Mark III and the I-Suit have taken part in NASA's annual Desert Research and Technology Studies (D-RATS) field trials, during which suit occupants interact with one another, and with rovers and other equipment.

Mark III

[edit]

The Mark III is a NASA prototype, constructed by ILC Dover, which incorporates a hard lower torso section and a mix of soft and hard components. The Mark III is markedly more mobile than previous suits, despite its high operating pressure (57 kPa or 8.3 psi), which makes it a "zero-prebreathe" suit, meaning that astronauts would be able to transition directly from a one-atmosphere, mixed-gas space station environment, such as that on the International Space Station, to the suit, without risking decompression sickness, which can occur with rapid depressurization from an atmosphere containing nitrogen or another inert gas.

MX-2

[edit]

The MX-2 is a space suit analogue constructed at the University of Maryland's Space Systems Laboratory. The MX-2 is used[when?] for crewed neutral buoyancy testing at the Space Systems Lab's Neutral Buoyancy Research Facility. By approximating the work envelope of a real EVA suit, without meeting the requirements of a flight-rated suit, the MX-2 provides an inexpensive platform for EVA research, compared to using EMU suits at facilities like NASA's Neutral Buoyancy Laboratory.

The MX-2 has an operating pressure of 2.5–4 psi. It is a rear-entry suit, featuring a fiberglass HUT. Air, LCVG cooling water, and power are open loop systems, provided through an umbilical. The suit contains a Mac Mini[citation needed] computer to capture sensor data, such as suit pressure, inlet and outlet air temperatures, and heart rate.[55] Resizable suit elements and adjustable ballast allow the suit to accommodate subjects ranging in height from 68 to 75 inches (170–190 cm), and with a weight range of 120 lb (54 kg).[clarification needed][56]

North Dakota suit

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Beginning in May 2006, five North Dakota colleges collaborated on a new space suit prototype, funded by a US$100,000 grant from NASA, to demonstrate technologies which could be incorporated into a planetary suit. The suit was tested in the Theodore Roosevelt National Park badlands of western North Dakota. The suit has a mass of 47 pounds (21 kg) without a life support backpack, and costs only a fraction of the standard US$12,000,000 cost for a flight-rated NASA space suit.[57] The suit was developed in just over a year by students from the University of North Dakota, North Dakota State, Dickinson State, the state College of Science and Turtle Mountain Community College.[58] The mobility of the North Dakota suit can be attributed to its low operating pressure; while the North Dakota suit was field tested at a pressure of 1 psi (6.9 kPa; 52 Torr) differential, NASA's EMU suit operates at a pressure of 4.7 psi (32 kPa; 240 Torr), a pressure designed to supply approximately sea-level oxygen partial pressure for respiration (see discussion above).

PXS

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NASA's Prototype eXploration Suit (PXS), like the Z-series, is a rear-entry suit compatible with suitports.[59] The suit has components which could be 3D printed during missions to a range of specifications, to fit different individuals or changing mobility requirements.[60]

Suitports

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A suitport is a theoretical alternative to an airlock, designed for use in hazardous environments and in human spaceflight, especially planetary surface exploration. In a suitport system, a rear-entry space suit is attached and sealed against the outside of a spacecraft, such that an astronaut can enter and seal up the suit, then go on EVA, without the need for an airlock or depressurizing the spacecraft cabin. Suitports require less mass and volume than airlocks, provide dust mitigation, and prevent cross-contamination of the inside and outside environments. Patents for suitport designs were filed in 1996 by Philip Culbertson Jr. of NASA's Ames Research Center and in 2003 by Joerg Boettcher, Stephen Ransom, and Frank Steinsiek.[61][62]

Z-series

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Z-1 Series Suit

In 2012, NASA introduced the Z-1 space suit, the first in the Z-series of space suit prototypes designed by NASA specifically for planetary extravehicular activity. The Z-1 space suit includes an emphasis on mobility and protection for space missions. It features a soft torso versus the hard torsos seen in previous NASA EVA space suits, which reduces mass.[63] It has been labeled the "Buzz Lightyear suit" due to its green streaks for a design.

In 2014, NASA released the design for the Z-2 prototype, the next model in the Z-series. NASA conducted a poll asking the public to decide on a design for the Z-2 space suit. The designs, created by fashion students from Philadelphia University, were "Technology", "Trends in Society", and "Biomimicry".[64] The design "Technology" won, and the prototype is built with technologies like 3D printing. The Z-2 suit will also differ from the Z-1 suit in that the torso reverts to the hard shell, as seen in NASA's EMU suit.[65][66]

In fiction

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1950 issue of Wonder Story Annual with a woman wearing a spacesuit on the cover

Space suits are a common staple of science fiction.[67][68] They appeared in sf works as early as 19th century (Jules Verne's From the Earth to the Moon, 1865).[69]

See also

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References

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Bibliography

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Revisions and contributorsEdit on WikipediaRead on Wikipedia
from Grokipedia
A space suit, also known as a spacesuit, is a sealed, pressurized garment designed to protect astronauts from the extreme conditions of , including , extremes, , and micrometeoroids, while enabling mobility and during extravehicular activities (EVAs). It functions as a miniature, one-person , providing a breathable atmosphere, thermal regulation, and communication capabilities to sustain human life outside a spacecraft or . The history of space suits traces back to early 20th-century high-altitude efforts, with the first pressure suits developed in the around 1931 to enable pilots to survive low-pressure environments. In the United States, NASA's development accelerated with in 1958, where suits like the silver-colored were engineered for launch, re-entry, and basic protection, marking the first U.S. crewed spaceflights by 1961. Subsequent programs, such as Gemini and Apollo, introduced more advanced designs; the Apollo A7L suit, used from 1969, supported lunar surface EVAs with enhanced mobility and a backpack life support system, allowing astronauts to walk on the for up to eight hours. Space suits are categorized into two primary types: intra-vehicular activity (IVA) suits for use inside during launch and re-entry, which prioritize comfort and pressure protection, and (EVA) suits for spacewalks, which include robust backpacks and multi-layered construction for full environmental isolation. NASA's current (EMU), in use since 1983 including on the since 1998, exemplifies EVA suits with 14 layers of fabric, including insulation, a liquid cooling garment, and a hard upper for structural support. Key components of a typical EVA space suit include the for visibility and oxygen delivery, gloves for dexterity in handling tools, the lower torso assembly with boots for mobility, and the primary life support subsystem (PLSS) backpack that recycles air, removes , and regulates temperature for up to eight hours. These suits weigh approximately 280 pounds (127 kg) on but are weightless in microgravity. Looking ahead, is developing next-generation suits for the , such as the Exploration Extravehicular Mobility Unit (xEMU) and Axiom Space's AxEMU for lunar missions, incorporating improved flexibility, dust resistance for regolith, and modular designs to support extended Mars explorations by the 2030s. These advancements aim to enhance safety and efficiency in deep space environments.

Physiological and Environmental Requirements

Primary Requirements for Survival

Space suits are essential for enabling extravehicular activity (EVA) by providing critical protection against the vacuum of space and its associated hazards, ensuring astronaut survival for durations typically up to 8 hours. The primary environmental threats include high-velocity micrometeoroids, ionizing radiation, temperature extremes ranging from -157°C (-250°F) to 121°C (250°F), and the risk of vacuum-induced ebullism, where reduced pressure causes dissolved gases in bodily fluids to form bubbles, leading to tissue swelling and potential organ damage. To counter micrometeoroids, which can travel at speeds up to 29 km/s (64,000 mph) and penetrate unprotected surfaces, suits incorporate multi-layer outer garments such as the Integral Thermal Micrometeoroid Garment (ITMG), composed of materials like Kevlar for impact resistance. Radiation protection is provided through suit shielding that attenuates galactic cosmic rays and solar particle events, though full shielding is limited by mass constraints, focusing instead on reducing skin and blood-forming organ exposure during accidental bursts. Thermal control systems, including multi-layer insulation and liquid cooling garments, maintain internal temperatures between 18°C and 27°C despite external fluctuations, preventing hypothermia or hyperthermia. A core survival requirement is maintaining internal suit pressure to prevent hypoxia and tissue damage from exposure. Standard EVA suits operate at approximately 29.6 kPa (4.3 psi) with 100% oxygen atmosphere, sufficient to deliver adequate of oxygen of 29.6 kPa (equivalent to about 30% oxygen at sea-level pressure) for respiration while minimizing risk during transitions from environments. This pressure level also mitigates by keeping bodily fluids below their boiling point, avoiding the swelling that could occur at pressures below 6.3 kPa (0.9 psi). The suit's pressure bladder layer, typically made of neoprene-coated , seals the body to create this habitable microenvironment, with redundant seals and valves to handle potential leaks. Mobility is another vital requirement, allowing astronauts to perform tasks such as tool manipulation, sample collection, and surface traversal without excessive . Suits must limit joint to enable natural ranges of motion; for instance, joints require approximately 20-30 Nm of for flexion and abduction movements to simulate unsuited performance, as measured in torque-angle testing protocols. Bearings and convolute designs in suit joints reduce resistance, ensuring that upper body mobility supports overhead work and lower body mobility facilitates lunar or Martian locomotion at reduced gravity. Finally, space suits must adhere to mass and volume constraints to fit within launch and storage limitations. Typical EVA suits, including backpacks, have a total mass of 100-150 kg under gravity, balancing protection with launch efficiency; for example, the (EMU) masses about 127 kg (280 lb). Stowed volumes are minimized to approximately 1-2 m³ per suit for integration into vehicle airlocks or lockers, using collapsible designs that allow compact packaging without compromising deployment readiness.

Operating Pressure and Gas Composition

Space suits for (EVA) have evolved in their operating pressure and gas composition to optimize safety, mobility, and physiological compatibility. Early designs, such as those used in , employed 100% oxygen at 3.7 psi (25.5 kPa) to provide a breathable atmosphere while serving primarily as a backup against cabin depressurization. This low-pressure, pure-oxygen environment was retained in the Apollo program's A7L suits for lunar EVAs, also at 3.7 psi, balancing oxygen delivery with the need to limit suit ballooning and joint restriction. Over time, designs shifted to slightly higher pressures, such as the 4.3 psi (29.6 kPa) in NASA's (EMU) used on the and , to enhance safety margins against leaks while still using pure oxygen for its high of O2 (equivalent to approximately 29% O2 at sea-level ) and reduced risk of fire compared to mixed gases. Current EVA suits typically operate within 29.6–34.5 kPa (4.3–5.0 psi) of pure oxygen, a range that maintains adequate oxygenation—delivering a partial pressure of oxygen of 29.6–34.5 kPa (equivalent to approximately 29–34% oxygen at sea-level pressure)—while minimizing the physical effort required for movement. The selection of this pressure regime directly influences suit performance through fundamental gas laws, particularly , which governs the behavior of the suit's internal gas under changing . is expressed as
P1V1=P2V2P_1 V_1 = P_2 V_2
where PP is and VV is at initial (1) and final (2) states, assuming constant . In space suit design, this law applies to the fixed- suit enclosure: as external pressure drops to near-vacuum (effectively 0 psi), the internal gas expands to maintain equilibrium, but the suit's rigid structure constrains , resulting in sustained internal . This creates a significant pressure differential—typically from Earth's atmospheric 14.7 psi (101 kPa) to the suit's 4.3 psi—that induces fabric tension and volumetric effects, increasing by up to several Newton-meters per during flexion. For instance, calculations using illustrate how transitioning from 14.7 psi to 4.3 psi amplifies stiffness in soft components, requiring increases of 20–50% at the or to overcome the inflated , thereby informing reinforcement strategies for dexterity.
To mitigate (DCS) from nitrogen off-gassing during pressure reduction, astronauts follow rigorous prebreathing protocols before donning the suit and commencing EVA. These involve inhaling pure oxygen for 1–2 hours, often at a reduced cabin pressure of 10.2 psi (70.3 kPa), to denitrogenate tissues and lower DCS risk to below 1%. In NASA's standard procedure for ISS operations, crew members prebreathe 100% oxygen for approximately at full cabin pressure (14.7 psi), followed by exercise-enhanced denitrogenation at 10.2 psi to accelerate washout, enabling safe transition to the suit's 4.3 psi environment without prolonged exposure risks. This protocol, refined through biophysical modeling, ensures the gradient does not exceed safe thresholds for bubble formation in the bloodstream.

Physiological Effects of Exposure

Exposure to the vacuum of space without protection triggers severe physiological responses due to the absence of and oxygen. One of the primary immediate effects is , where the low pressure causes dissolved gases in bodily fluids to form bubbles, leading to swelling and the boiling of fluids at the surface of the body. This occurs at pressures below the of approximately 6.3 kPa (47 mmHg), the threshold where the of at body temperature (37°C) equals , causing and to boil first. results in rapid subcutaneous swelling, potentially doubling the body's volume, and disrupts normal circulation and tissue function. The lack of external pressure also exacerbates respiratory and cardiovascular failures. Without a spacesuit, air in the lungs expands violently if held, risking rupture of alveoli and , while exhaling leads to immediate hypoxia from oxygen depletion as no breathable air is available. Hypoxia causes loss of consciousness within 10-15 seconds due to cerebral anoxia, as blood oxygen levels plummet and cannot be expelled, potentially leading to if builds in tissues. At the , the threshold of 6.3 kPa marks the point where these effects become inevitable without pressurization, underscoring the narrow survival margin in . Animal experiments provide critical insights into these acute effects. In 1965 NASA tests, chimpanzees exposed to near-vacuum conditions (decompressed to less than 2 mmHg in 0.8 seconds) for up to 150 seconds demonstrated symptoms like limb spasms, loss of coordination, and cardiovascular collapse but recovered fully within 4 hours upon recompression without permanent neurological harm. These studies revealed that while brief exposures (under 3.5 minutes in some cases) allowed recovery without permanent neurological harm, prolonged vacuum led to fatal and anoxia, informing human safety protocols. Beyond immediate threats, unprotected or inadequately protected exposure in space contributes to long-term physiological deterioration. Microgravity induces bone density loss at a rate of 1-2% per month in weight-bearing bones like the femur and spine, due to reduced mechanical loading and altered calcium metabolism, potentially leading to osteoporosis upon return to Earth. Additionally, unshielded exposure to ultraviolet and ionizing radiation increases lifetime cancer risk, with NASA estimates indicating approximately a 1% elevation in fatal cancer probability for a 6-month mission, primarily from galactic cosmic rays and solar particle events damaging DNA. These effects highlight the necessity of comprehensive protection to mitigate both acute and chronic hazards of the space environment.

Design Principles and Types

Soft Vacuum Suits

Soft vacuum suits, also known as soft suits, are flexible pressure garments primarily constructed from layered fabrics that maintain to form a habitable environment against the of . These suits function as a sealed , relying on the elasticity and strength of materials to retain gas and provide structural integrity without rigid components for the main body. The core of soft suits involves a multi-layered garment, typically comprising 5 to 13 layers to achieve retention, mobility, and . The innermost layer is a gas-tight , often made of polyurethane-coated or urethane-coated , which prevents oxygen leakage and is approximately 0.2 to 0.5 mm thick. Surrounding this is a restraint layer of woven fabrics like Dacron or neoprene-coated , designed to counteract the outward force of and prevent excessive expansion, with the total garment thickness ranging from 2 to 3 mm. Additional outer layers, such as tricot or aluminized Mylar, provide and micrometeoroid resistance, contributing to the suit's overall flexibility. In terms of pressure vessel mechanics, soft vacuum suits operate as a flexible where internal —typically 29.6 to 34.5 kPa (4.3 to 5.0 psi) of pure oxygen—balances the external , requiring the fabric seams to withstand significant tensile loads to avoid bursting. Seams are reinforced with double-stitched or bonded urethane coatings, achieving burst resistance on the order of 100 kN/m or higher to ensure margins against puncture or overpressurization. This design simplifies manufacturing compared to rigid alternatives but demands precise to maintain uniform pressure distribution across the body. A key advantage of soft vacuum suits is their low mass and inherent flexibility, with total suit weights often ranging from 15 to 80 kg, enabling easier donning and transport while allowing greater freedom of movement in unpressurized configurations. For instance, the Gemini G4C suit, a pure soft used in early extravehicular activities, weighed approximately 16 kg and featured convoluted joints in the fabric to enhance bendability. However, when pressurized, these suits suffer from ballooning, where the bladder expands outward, leading to stiffness and significant loss in joint mobility, particularly in the shoulders and elbows, which increases metabolic cost for tasks like tool handling. Examples of soft vacuum suits emphasize their role in intravehicular and short-duration extravehicular operations, such as the Gemini program's G4C, which relied entirely on layered and fabrics for containment without hard elements in the torso. While some designs incorporate soft upper torso sections for partial flexibility, pure soft configurations like the G4C highlight the trade-offs in simplicity versus performance limitations under full .

Hard-Shell Suits

Hard-shell suits represent a class of spacesuits featuring rigid, articulated structures primarily constructed from metal or composite materials to enhance protection and facilitate movement in the and extreme conditions of . These suits maintain a constant internal volume through mechanical joints, mitigating the expansion and stiffness that pressurized soft suits experience, thereby supporting extended extravehicular activities (EVAs). Exemplified by experimental prototypes like NASA's AX-5 and Mark III, hard-shell designs prioritize structural integrity for operations on the lunar surface or in planetary environments. The core structure of hard-shell suits utilizes materials such as anodized aluminum for the and limb shells, offering high strength-to-weight ratios and resistance to . Additional components incorporate composites, alloys, and synthetic coatings to optimize and properties, as seen in the AX-5 suit developed at NASA's in the late . These materials form a robust that protects against punctures and abrasions, evolving from earlier high-altitude pressure suits that introduced rigid elements for testing. Mobility in hard-shell suits is enabled by specialized joint systems, including spherical and toroidal bearings that align with human kinematics to minimize requirements during motion. For instance, the AX-5 employs round, toroidal joints at the shoulders and hips, providing near-unsuited for abduction and essential to tasks like sample collection or handling. This approach builds on bearing technologies from predecessor suits, such as the roller bearings in the Apollo A7L's shoulder joints, which were refined from high-altitude prototypes to support low- arm movements under pressure. A primary advantage of hard-shell construction is its superior impact resistance, where the rigid shell distributes forces from high-velocity particles, outperforming fabric layers in withstanding strikes common . The also reduces pressure-related stiffness, allowing operation at higher internal pressures—up to 8.3 psia (57 kPa) in the AX-5—without significant mobility loss, thus eliminating the need for lengthy pre-breathing procedures and enabling more efficient EVAs. In comparison, soft suits often face greater flexibility constraints under similar conditions. However, hard-shell suits present challenges, including elevated mass typically ranging from 70 to 100 kg (including backpack), which demands advanced locomotion aids in partial gravity to avoid . Their intricate , involving precision machining of joints and integration of composites, increases development costs and maintenance complexity compared to softer alternatives. Despite these drawbacks, ongoing refinements aim to balance protection with usability for future missions.

Hybrid and Skintight Suits

Hybrid space suits integrate rigid and flexible components to optimize protection, pressure containment, and mobility during extravehicular activities. A prominent example is NASA's (EMU), which features a hard upper constructed from an aluminum alloy shell for structural support and protection, paired with a soft lower assembly made of multi-layered and fabrics for enhanced flexibility in the legs and waist. This design maintains an operating pressure of 4.3 pounds per square inch differential (psid), or approximately 29.6 kPa, while allowing astronauts to perform tasks requiring both torso stability and lower-body articulation. Skintight suits, also known as mechanical counterpressure (MCP) designs, represent an alternative approach by using form-fitting elastic garments to apply direct compression to the body, eliminating the need for internal gas inflation and its associated bulk. These suits typically employ materials such as nylon-spandex blends or advanced polymers to generate counterpressures in the range of 25-40 kPa, sufficient to counteract vacuum-induced physiological effects like without causing tissue swelling. Unlike purely soft vacuum suits, MCP systems avoid gas expansion issues, enabling a sleeker profile that conforms to the wearer's movements. The primary advantages of hybrid and skintight suits include substantially reduced overall mass—potentially below 50 kg for full systems—and greater , facilitating more natural locomotion and dexterity compared to traditional gas-pressurized suits weighing over 130 kg. Prototypes like the MIT Bio-Suit demonstrate these benefits through layered elastic fabrics and tension elements that mimic muscle action, targeting enhanced mobility for planetary exploration. However, key challenges persist in ensuring uniform pressure application, with tests revealing significant spatial variability (up to 20% differences across body regions) due to fabric stretching and anatomical contours, which can compromise safety and comfort. Ongoing research focuses on active materials and modeling to mitigate these inconsistencies.

Key Components and Technologies

Helmet and Visor Systems

The in a space suit functions as a rigid for the head, providing structural integrity, , and an interface for visibility and communication systems while maintaining the suit's internal pressure. Constructed primarily from for its impact resistance and optical clarity, the helmet shell is bonded to a metallic that locks into the suit , ensuring a sealed connection capable of withstanding conditions. Ventilation and oxygen distribution occur through integrated manifolds, with purge valves allowing for emergency depressurization. Visor systems are multilayered assemblies integrated into the helmet, featuring an inner transparent or acrylic pressure-retaining and an outer protective assembly. The outer includes a shield and a sun coated with a thin layer of to reflect and , thereby mitigating thermal loads and solar exposure. This coating, applied via , transmits a substantial portion of visible —typically around 60-70%—to preserve the astronaut's while blocking over 90% of harmful solar spectrum components beyond the visible range. For example, in NASA's (), the assembly achieves this balance to support extended extravehicular activities without compromising eye safety. Heads-up displays (HUDs) are increasingly incorporated into helmet designs to overlay critical data, such as oxygen reserves, suit pressure, and biomedical , directly onto the astronaut's . These systems utilize compact LED projectors or micro-displays mounted within the , collimating information for focus at infinity to minimize eye strain during tasks. Development efforts for the xEMU emphasize full-color, high-resolution projections tailored to the constrained volume, enhancing without requiring head repositioning. NASA's Suit User Interface Technologies for Students (SUITS) challenge has prototyped such interfaces, projecting alphanumeric and graphical elements via optics. Pressure seals at the helmet-torso interface rely on a neck ring assembly, often fabricated from aluminum alloy for strength and low weight, paired with elastomeric gaskets such as silicone compounds to achieve airtight integrity. These gaskets compress against the neck dam or suit collar, accommodating minor misalignments and thermal expansions while rated for repeated pressurization cycles—typically dozens in operational testing. The design incorporates interlocking mechanisms, like sliding teeth or bayonet locks, to secure the helmet firmly against differential pressures up to 4.3 psi, as maintained in pure oxygen environments. Anti-fog measures are essential for clarity in the humid, low-flow conditions inside the . Interior surfaces receive chemical coatings, such as hydrophilic polymers, that promote even film distribution rather than droplet formation, often supplemented by directed oxygen flows from suit . Emerging solutions aim for durable, transparent films maintaining over 70% visible light transmission post-application, resistant to cleaning solvents like or mild detergents used in . In some configurations, sublimator-based cooling indirectly aids by controlling overall , though primary defogging relies on the coatings and ventilation. Historically, the Apollo-era helmets exemplified early constraints in these systems, with a shell of limited internal volume—approximately 0.3 cubic feet—enclosing the head in a fixed orientation that restricted lateral and vertical movements to roughly 30 degrees due to the rigid attachment and lack of internal adjustability. This prioritized retention and ballistic over mobility, influencing subsequent iterations toward more ergonomic volumes and bearings.

Glove and Mobility Mechanisms

Space suit gloves are critical for enabling astronauts to perform precise manipulations during extravehicular activities (EVAs), typically consisting of 5 to 7 layers to balance pressurization, protection, and dexterity under operational pressures of 4.3 psi. The innermost layer is a or urethane bladder that maintains internal pressure and prevents ballooning, while the restraint layer, often made of or similar high-strength fabric, constrains the bladder to reduce torque during flexion. Outer layers include a thermal micrometeoroid garment (TMG) with Chromel-R fabric for abrasion resistance and thermal insulation, ensuring hand protection in the vacuum of space. These multi-layered designs impose significant biomechanical demands, with finger flexion requiring forces of approximately 10-15 due to the differential and , leading to reduced of 50-70% compared to bare-handed performance. To mitigate this, articulated joints in gloves incorporate convolute ridges and synthetic joints at the metacarpophalangeal (MCP) knuckles, which lower flexion by up to 25% relative to baseline designs and improve dexterity scores from 6 to 6.75 out of 10. Innovations such as shape-conforming structures further reduce by distributing more evenly, allowing for prolonged fine motor tasks without excessive strain. Mobility mechanisms in space suits extend beyond gloves to include articulated joints at major body segments, such as the and , designed to accommodate 90° flexion while countering from suit pressurization. These joints often employ cable actuators or gas-lubricated bearings to minimize friction, with hip and knee designs providing 20-40 Nm of capacity to enable walking and tool handling in microgravity. Overall, such systems address a 50-70% loss in Earth-like mobility, primarily due to pressure-induced , by optimizing joint geometry for reduced resistance during EVA maneuvers. NASA's Astronaut Glove Challenge, culminating in 2009 with awards to innovative designs, spurred advancements like flexible restraint systems that enhanced joint mobility and reduced hand fatigue during simulated EVAs. Subsequent developments, including 2020-funded prototypes from the , incorporated 3D-printed joints for gloves and arms, allowing customizable flexion with up to 40% less effort than traditional rigid components. These efforts prioritize seminal contributions from challenges and prototypes to improve overall suit dexterity without compromising safety.

Life Support and Thermal Control Systems

The primary life support module, commonly known as the Portable Life Support System (PLSS), is a backpack-mounted unit that sustains the during extravehicular activities (EVAs) by providing breathable oxygen, removing , and managing . In the Extravehicular Mobility Unit (), the PLSS draws from high-pressure gaseous oxygen tanks to supply pure oxygen for suit pressurization and respiration, with a ventilation flow rate of approximately 0.17 cubic meters per minute (10 m³/h) at 29.6 kPa suit to support metabolic needs and CO₂ washout. is scrubbed using (LiOH) canisters, which chemically absorb CO2 through the reaction 2LiOH + CO2 → Li2CO3 + H2O, with each canister providing capacity for up to 8 hours of EVA operation by removing about 0.68 kg of CO2. The overall PLSS for the weighs approximately 32 kg when fully loaded, enabling 7-8 hours of autonomous operation including donning, EVA, and doffing phases. Thermal control in space suits prevents overheating from metabolic heat (typically 200-800 W) and solar radiation while avoiding excessive cooling in shadowed areas. This is achieved primarily through a liquid cooling garment (LCG), a mesh undergarment with embedded plastic tubing that circulates chilled to absorb body heat via . In the , the LCG operates at a flow rate of about 1.9 liters per minute with inlet temperatures of 13-18°C, extracting up to 500 W of heat before routing it to the sublimator for rejection. Complementing the LCG, (MLI) consists of 10-20 thin alternating layers of reflective foil (e.g., aluminized Mylar) and spacer material (e.g., Dacron netting) wrapped around the suit's exterior, reducing radiative by a factor of 50-100 compared to a single layer. Humidity control integrates with the oxygen ventilation loop, where exhaled moist air passes through a condenser to condense , maintaining relative at 50-70% to prevent fogging and discomfort; excess condensate is vented or recycled. addresses urine and fecal elimination to avoid during EVAs lasting up to 8 hours. is collected via a (MAG), an absorbent undergarment similar to a that holds up to 2 liters using superabsorbent polymers, while fecal containment relies on adhesive bags or integrated pouches attached to the suit's lower torso, designed for minimal output through pre-EVA dietary restrictions. Heat from the LCG and ventilation systems is rejected to via a porous plate sublimator , where feedwater freezes and sublimates directly into , providing non-condensable to dissipate 700-2000 W without moving parts. Power for the PLSS and suit electronics is supplied by rechargeable batteries, with the EMU historically using silver-zinc (AgZn) cells due to their high of 100-150 Wh/kg. The EMU's AgZn , consisting of 11 series-connected cells, delivers about 0.8 kWh at 22-28 V, supporting 8 hours of operation at an average draw of 70-100 for pumps, fans, controllers, and communications. Modern upgrades incorporate lithium-ion batteries for improved rechargeability and safety, maintaining similar capacity while reducing mass by 20-30%.

Historical Development

Early High-Altitude and Prototype Suits

The origins of space suits trace back to high-altitude aviation pressure suits developed in the 1930s to combat hypoxia during stratospheric flights. Aviator Wiley Post, in collaboration with the B.F. Goodrich Company, pioneered the first practical full-pressure suit using inner rubber bladders and an outer canvas layer to maintain bodily pressure. This suit allowed Post to achieve altitudes exceeding 40,000 feet (12,192 meters) in 1935 aboard his , marking a critical step in personal protective gear for extreme environments. During , the U.S. Army Air Forces advanced these concepts amid demands for operations at 30,000–40,000 feet, beginning with oxygen delivery systems like the A-14 demand mask, which supplied regulated oxygen to pilots via a facepiece and harness. These masks addressed immediate breathing needs but highlighted limitations in full-body protection, prompting evolution toward integrated suits by the mid-1940s. Developments included partial-pressure suits for B-29 Superfortress crews, such as early models tested for cabin decompression scenarios, providing graduated compression to limbs and torso to prevent and maintain consciousness. In the 1950s, prototypes bridged aviation and spaceflight requirements. The David Clark Company developed the Model 2 full-pressure suit for the X-15 hypersonic research aircraft, operating at 3.5 psi (24 kPa) with a neoprene-coated nylon bladder and restraint layers for mobility during flights reaching the edge of space. Concurrently, the Soviet Zvezda design bureau created the SK-1 suit for the Vostok program, a soft full-pressure suit pressurized to approximately 0.3 atmospheres (300 hPa or 4.4 psi), incorporating a helmet, gloves, and boots for pilot protection during launch and reentry. The SK-1 was first used by Yuri Gagarin on Vostok 1 in 1961. A pivotal milestone occurred in 1960 with NASA's Mercury program suit, an iteration of the Navy Mark IV design adapted as the first dedicated orbital pressure garment, which underwent testing to simulate exposure and validate seals against pressures as low as 10^-5 . These tests confirmed the suit's ability to sustain for short-duration missions, establishing benchmarks for tolerance.

Soviet and Russian Space Suits

The development of Soviet space suits began in the early 1960s with the Berkut suit, a soft garment designed specifically for (EVA) during the Voskhod program. Introduced for the mission in March 1965, the Berkut enabled cosmonaut to perform the world's first spacewalk, lasting approximately 12 minutes. The suit operated at a of 0.4 atmospheres (about 5.8 psi) and featured an open-cycle (LSS) in a backpack that supplied oxygen for both breathing and cooling, with excess gas vented through a to remove heat, moisture, and . This design, derived from the earlier Sokol suits used in Vostok flights, prioritized simplicity but highlighted challenges like suit stiffening under , which complicated re-entry for Leonov. Following the Berkut, the Yastreb suit represented an evolution toward dedicated EVA capabilities, entering operational status in 1969 as the Soviet Union's first purpose-built extravehicular suit. Developed by the Zvezda design bureau starting in 1965, it incorporated a compact LSS backpack for limited mobility and was worn by cosmonauts Yevgeny Khrunov and Aleksei Yeliseyev during the Soyuz 4/5 mission to facilitate crew transfer between docked spacecraft without full cabin depressurization. Although designed for up to 3 hours of EVA with a suit pressure similar to the Berkut's 0.4 atmospheres, the Yastreb saw no actual spacewalks and was used primarily for intra-vehicle operations, marking a transitional step before more advanced models. Its design emphasized enhanced joint flexibility over the Berkut but was ultimately superseded due to limitations in duration and redundancy. The series, introduced in 1977, became the cornerstone of Soviet and later Russian EVA operations, evolving into the hybrid Orlan-M model that debuted in 1997 and remains in use today. This semi-rigid suit features a hard aluminum torso for structural integrity combined with flexible fabric limbs, allowing cosmonauts to enter from the rear for easier donning in microgravity. The Orlan-M's portable (PLSS) provides redundant oxygen supply at 5.8 psi (40 kPa), supporting up to 7 hours of autonomous EVA, with a total mass of 110 kg and compatibility for cosmonauts between 165 and 190 cm in height. Over its service life of 5-6 years per suit, it has enabled more than 200 EVAs across Salyut, , and the (ISS), including over 60 on the ISS alone as the primary Russian EVA garment. Key enhancements include dual oxygen tanks for redundancy and political design elements, such as hammer-and-sickle emblems on early models symbolizing Soviet heritage, later adapted to Russian . A tragic incident underscoring the importance of pressure protection occurred during the mission in 1971, when cosmonauts , Vladislav Volkov, and perished due to a valve failure that caused rapid cabin during re-entry. Unlike EVA suits, the crew was not wearing full pressure garments—relying instead on cabin atmosphere to accommodate three occupants—leading to their exposure to near-vacuum conditions for over a minute, resulting in fatal hypoxia. This event, caused by a premature opening of the equalization at 150 km altitude, prompted redesigns in subsequent Soyuz vehicles to mandate pressure suits during critical phases and improved valve reliability.

United States Space Suits

The space suit program began with NASA's , where the G3C soft pressure suit was developed for missions from 1961 to 1963 to protect astronauts against cabin depressurization during suborbital and orbital flights. This full-pressure suit operated at 3.7 psi using 100% oxygen, featuring a side-entry design with flexible neoprene-coated layers for basic mobility inside the . For (1961-1966), the suit evolved into the G4C configuration to support extravehicular activities (EVAs), first demonstrated during in 1965 when astronaut Edward White performed the initial U.S. spacewalk. The G4C retained the 3.7 psi operating pressure of the G3C but incorporated enhancements like redundant zippers for easier entry, improved shoulder joints for better arm mobility, and an integrated thermal micrometeoroid garment for EVA protection, enabling up to 25 minutes of untethered activity. The Apollo program's A7L suit, used from 1969 to 1972, marked a shift to hybrid construction with a hard upper torso made of aluminum for structural integrity and increased pressurization stability during lunar surface operations. Operating at 3.7 psi, the A7L supported 10 moonwalks across through 17, with features like dust-resistant overshoes to mitigate lunar abrasion and a total system mass of 82 kg including the portable backpack. NASA's Extravehicular Mobility Unit (EMU), introduced in the 1980s for Space Shuttle missions and continuing on the International Space Station, features a modular design with separable hard components for maintenance and operates at 4.3 psi to balance mobility and decompression sickness risk. This suit has enabled over 200 EVAs for ISS assembly and maintenance since the 1990s, accumulating thousands of hours of extravehicular time. A key addition was the Simplified Aid for EVA Rescue (SAFER) jetpack, first tested in 1994 and later used in Hubble Space Telescope repair missions to provide untethered propulsion for self-rescue during contingencies. Following the , initiated development of the Exploration Extravehicular Mobility Unit (xEMU) in the 2010s for lunar missions, incorporating advancements like integrated LED lighting in the for enhanced visibility in shadowed regions and redesigned gloves with improved dexterity and thermal protection for prolonged surface tasks.

Current and Emerging Models

NASA and International Suits

's () continues to support extravehicular activities (EVAs) on the (ISS), with ongoing maintenance and component upgrades to extend operational life through at least 2030. As of 2025, enhancements include refined battery servicing and water replenishment systems to mitigate performance degradation, though the aging fleet has experienced leaks and component failures leading to EVA cancellations in 2024, with spacewalks resuming early in 2025 after repairs. , the sole provider for sustainment, has focused on refurbishing backpacks and pressure garments to maintain reliability for up to 8-hour EVAs, amid challenges in and obsolescence management. For lunar missions under the , partners with on the Axiom (AxEMU), a next-generation suit debuting for Artemis III. The AxEMU incorporates a hard upper for superior and mobility, enabling astronauts to perform tasks like drilling and sample collection at the , with an 8-hour EVA capability including contingency time. It features advanced thermal and protection layers, along with -resistant materials to shield against elevated exposure levels—up to 150 times Earth's surface —during prolonged surface operations. The design also addresses lunar abrasion through durable outer layers tested for dust resistance, reducing wear on seals and joints. Compared to the , the AxEMU offers reduced mass for improved handling in partial gravity, while accommodating a broader range of body sizes from the 5th percentile female to 95th percentile male. Internationally, the (CNSA) debuted the Feitian extravehicular suit in 2021 for EVAs on the , marking China's first independent spacewalk capability. This soft-type suit operates at approximately 30 kPa (4.3 psi) of pure oxygen, providing 6 to 8 hours of mobility for tasks like solar array maintenance and equipment installation, with integrated for thermal regulation and CO2 scrubbing. Collaborations involving the (JAXA) and CNSA under broader international frameworks have facilitated technology exchanges, though JAXA astronauts primarily use the EMU for ISS operations. The (ESA) contributes to suit development through joint testing and materials research, while utilizing modified EMU variants for astronaut training in facilities since the 2010s. As of November 2025, AxEMU prototypes have completed and underwater simulations, with plans for the first integrated EVA tests in 2026 ahead of Artemis III, focusing on mitigation and south pole-specific hazards like shadowed craters. EMU sustainment efforts ensure continued ISS operations, while international suits like Feitian support independent station activities, highlighting global advancements in EVA reliability.

Commercial and Private Sector Suits

The commercial space suit sector has seen significant innovation driven by private enterprises focused on , orbital missions, and lunar exploration partnerships, prioritizing affordability, rapid iteration, and passenger-centric design over traditional government specifications. SpaceX's intravehicular activity (IVA) suit, introduced in 2017 for the Crew Dragon , employs a soft, form-fitting structure with a signature black-and-white aesthetic to enhance crew mobility and aesthetics during commercial crew rotations. Designed in-house, the suit maintains a pressurized environment to safeguard astronauts against potential cabin depressurization, while its gloves enable precise interaction with controls on the vehicle's interfaces. By November 2025, this suit has supported approximately 20 crewed missions to low-Earth orbit, including rotations to the , ferrying over 80 astronauts as part of SpaceX's operational cadence. Axiom Space's Axiom (AxEMU), developed under a 2023 contract for the , is an extravehicular suit for lunar surface activities. Collaborating with since 2023, the design integrates sustainable, high-performance fabrics such as Re-Nylon for abrasion resistance and thermal regulation, addressing the demands of extraterrestrial dust and extreme temperatures. With an estimated mass under 60 kg—substantially lighter than the 80 kg Apollo-era suits—the AxEMU emphasizes scalability and adaptability for diverse body types in commercial lunar ventures. Blue Origin's approach to suborbital space tourism on prioritizes lightweight flight suits over fully pressurized garments, leveraging the vehicle's environmentally controlled, pressurized crew capsule to ensure passenger safety during brief exposures to microgravity. These reusable suits, focused on comfort and minimal encumbrance, align with the system's emphasis on rapid turnaround and , enabling multiple daily operations where feasible. By late 2025, has achieved over 36 flights, including more than 15 crewed tourist missions, demonstrating the viability of commercial suborbital reusability. As of 2025, Virgin Galactic's next-generation suits, building on a 2019 partnership with , incorporate advanced knit fabrics for enhanced flexibility during 6G acceleration in suborbital profiles, with emerging industry explorations into mechanical counterpressure elements to reduce bulk and improve range of motion for tourist passengers.

Advanced Concepts and Prototypes

One prominent area of advanced space suit research involves mechanical counterpressure (MCP) suits, which apply pressure directly to the skin via a tight-fitting garment rather than gas inflation, potentially enhancing mobility and reducing overall suit mass. The MIT BioSuit, developed since the early 2000s, exemplifies this approach by using multi-layered textiles, including 3D-knitted structures from thermo-resistant fibers, to achieve uniform compression across the body. Researchers have explored active materials, such as electroactive polymers, integrated into to enable controllable counterpressure up to 30 kPa, sufficient to protect against vacuum exposure while allowing greater flexibility than traditional suits. This design offers the potential for significant mass reduction—estimated at up to 50% compared to gas-pressurized suits—by eliminating bulky inflation layers, though prototypes remain in testing as of 2025. Another innovative prototype is NASA's Suitport docking system, conceived in the as a rear-entry interface that connects the suit directly to a or exterior, bypassing traditional airlocks. By allowing astronauts to step into the suit from behind and seal it against the port, the system minimizes the transfer of contaminants like lunar or Martian dust into living spaces, addressing a key challenge for planetary exploration. Testing in analog environments, including Mars simulation facilities, has demonstrated its efficacy in reducing dust ingress during (EVA) cycles, with evaluations continuing into 2024 to refine compatibility with designs. NASA's Z-series prototypes, initiated in the under the Advanced project, represent iterative soft suit designs aimed at improving EVA performance for deep-space missions. These suits feature a soft upper with integrated mobility joints, some fabricated using additive techniques like to optimize flexibility and reduce weight. Operating at standard EVA pressures around 4.3 psi (29.6 kPa), the Z-2 and subsequent models incorporate variable stiffness elements in joints to enhance , achieving up to 90% of bare-handed mobility in key areas like shoulders and hips during tests. Emerging developments as of 2025 focus on additive manufacturing for personalized suit components and smart fabrics for integrated health monitoring. NASA's efforts include custom-fit gloves and joint elements, as demonstrated in 2024 prototypes that use digital scans to tailor pressure garments, reducing production time and improving fit for diverse physiques. Complementing this, smart fabrics embedded with sensors—such as strain gauges and biosensors woven into multi-layer textiles—enable real-time tracking of physiological parameters like , respiration, and suit integrity, enhancing safety during extended EVAs on the or Mars.

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