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NASA NTRSDate not supplied

xEMU Suit Integrated Audio Communications System: Ambient and EVA Pressure Testing System Performance

Testing across several airlock and EVA thermal and pressure scenarios has demonstrated that the Integrated Audio System of NASA’s Exploration Extravehicular Mobility Unit (xEMU) spacesuits transmits and receives intelligible audio communications without the use of a commcap or similar worn device. The xEMU audio system consists of internal loudspeakers and digital microphones (Integrated Communications System –ICS) combined with an adaptive Acoustic Echo Canceller (AEC), outbound voice operated transmission (VOX), and automatic gain control (AGC). Transducers are mounted in an “exploded commcap” configuration with helmet-attached speakers near the ears and three microphones positioned at the collar. The AGC removes inbound audio signals (e.g.,suit, Mission Control, Lander, C&W tones) from the outbound comms stream, reducing echo and feedback (squeal) in low-noise suit environments. The reduction of worn communication equipment increases crewmember comfort, range of movement, and situational awareness. However, test results also highlight the need for proper fan, duct, pump, and gas flow integration with suit acoustics and audio. Ductwork may serve as waveguides for various component and structure-borne noise. Sharply angled ducts can generate turbulent-flow noise. Gas flow from inlets above the crewmember’s head can generate noise when cascading over the faceplate and collar (or commcap) microphones. Sufficient acoustic noise levels (1) require increased gain to boost inbound audio, and (2) may distort signals resulting in AEC disruption or artifacts. Suit-noise levels decline with reduced pressure (density), but then elevated speech and audio effort/power become necessary. Whether the Integrated Audio System, commcap, or other device is used, suit acoustic noise can mask speech in outbound comms. This reduces intelligibility and requires other AECs/devices to suppress comms noise. Yet, adjusting a few components may yield significant improvement. We discuss xEMU audio functionality, demonstrate how acoustical treatment combined with inbound signal conditioning improved clarity during tests, and discuss future modifications.

xEMU↗
NASA NTRSDate not supplied

xEMU Thermal Vacuum Testing Overview

The Exploration Extravehicular Mobility Unit (xEMU) project was the culimation of over a decade of spacesuit development that was performed in-house at the NASA Johnson Space Center. This project reached a level where almost fully completed development fidelity spacesuits had been designed, assembled and tested in an integrated configuration. The xEMU Development-Verification-Test (DVT) hardware was assembled into two different xEMU test articles and underwent a series of thermal-vacuum tests at the Johnson Space Center’s Chamber B. These tests not only gathered data on thermal performance, but also exercised the life support system, communication system, suit information systems, and suit avionics. This complex test has and will continue to produce many meaningful reports ranging from component level test results (for example on spacesuit boots), test design of heater cages to simulate thermal environments for a spacesuit test article, and higher level thermal performance of subsystems (such as the Portable Life Support System) or the entire assembly. This paper provides an overview of the test configuration and also top level results from this highly successful integrated test of the xEMU.

PLSS↗
NASA NTRSDate not supplied

Advanced Space Suit Sizing Considerations

Fitting a space suit to a person could be considered an art form. Establishing a repeatable fitcheck process to accommodate the full anthropometric range of test subjects for a single suit design is a critical process to be able to prove suit functionality. Suited test subjects can have different preferences on how they fit inside a suit, and different suited test environments can lead to differences in certain suit sizing accommodations. Throughout this paper, the process of achieving an acceptable suit fit for test subjects will be discussed, along with sizing considerations for changes in suit design and test environments. Lessons learned from the Exploration Extravehicular Mobility Unit (xEMU) will be used to describe specific examples, along with key takeaways from additional NASA prototype mobility space suits. The suit fitcheck process starts with utilizing the anthropometric measurements of a test subject to evaluate their relation to the dimensions of space suit hardware in creating a predicted suit sizing configuration. From here, subjective comments and test team observations drive iterations to the suit sizing configuration to culminate in an acceptable suit fit for performance of further test evaluations. Understanding the relation of subjective comments to their impact on altering suit sizing is critical in establishing an acceptable suit fit.

spacesuit↗
NASA NTRSDate not supplied

NASA Extravehicular Activity Technology Roadmaps for Exploration

The National Aeronautics and Space Administration (NASA) has developed and matured many technologies over the decades to advance extravehicular activity (EVA) systems. Over the last 15 years, major steps were taken to advance the technology with the Exploration Extravehicular Mobility Unit (xEMU) government reference design at the Johnson Space Center (JSC) in Houston, Texas. The xEMU builds on the lessons learned of the Apollo, Space Shuttle, and International Space Station (ISS) EMUs, evolving the technology to increase performance for extreme environments. As NASA sets its goals toward Earth’s Moon and Mars, a spacesuit design tolerable of gravity and dust will be needed for these adverse environments. NASA has used roadmaps as the means of documenting actionable plans for strategizing technology developments needed to meet NASA’s mission and goals. To help reach and create a sustained presence on the Moon, NASA procured EVA services from industry through the Exploration EVA Services (xEVAS) contract. These services include certified contractor-provided spacesuits, tools, equipment, vehicle interfaces, and support to training and real-time operations. NASA will now focus on a mission to Mars. NASA leadership has set goals and objectives related to the Agency’s vision and a Moon to Mars (M2M) strategy. This paper presents an organizational framework to provide insight into how NASA’s vision is realized. Additionally, this paper covers the maturation and development of the spacesuit technology and reveals the EVA technology roadmaps for the M2M Program. These EVA roadmaps visualize an actionable path to EVA capabilities needed for Mars exploration.

Cinda Chullen↗
NASA NTRSDate not supplied

Evaluation of Long-Term Storage Stability and Operational Efficiency of Rapid Cycle Amine Adsorbents

With the recent incorporation of Mars Extravehicular Activity (EVA) into the 2025 NASA roadmap, Rapid Cycle Amine (RCA) technology advancement within the Exploration Extravehicular Mobility Unit (xEMU) applies to both the upcoming Lunar Artemis missions and future human exploration of Mars. The incorporation of commercial spacesuit vendors to service NASA’s crewed-space programs since 2021 has increased the demand for regenerable, RCA-based carbon dioxide (CO2) and humidity control adsorbents. The regenerable RCA subunit is the most advanced, long-term solution for CO2 removal and humidity control, enabling both lunar and Martian EVAs. The adsorbent selected for use within the RCA unit must exhibit sufficient storage stability and operational efficiency for prolonged missions. As XploSafe worked to simultaneously develop both a recirculating sub-atmospheric test rig and adsorbents for the RCA system within the xEMU, several novel adsorbents were evaluated for long-term storage stability in support of future extended-duration missions. The chosen materials were periodically evaluated by nuclear magnetic resonance (NMR) spectroscopy, thermal desorption-coupled with gas chromatography/mass spectrometry (TD-GC/MS), and CO2 adsorption to assess long-term storage efficacy across various environmental storage conditions. NMR spectroscopy was utilized by extracting the active CO2 adsorbing chemical from the solid support with deuterated solvent and comparing the spectra over time for degradation and change. The solid adsorbents were also analyzed via TD-GC/MS to reveal any potential off-gassing chemicals over time. Additionally, XploSafe’s breakthrough test rig was utilized to dose the solid adsorbents with a 585 BTU/h metabolic rate flow-equivalent CO2 stream and monitored for 0–99% CO2 breakthrough. The performance metrics from the breakthrough analysis were compared over the storage study duration for CO2 removal and humidity control. Xplo-SA9T was evaluated for 24 months, whereas two additional adsorbent variants, MMPA-Sorbent and LPEI-Sorbent, were each evaluated for 12 months.

John R Tidwell↗
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 NTRSDate not supplied

Model Correlation and Thermal Analysis of xEMU Boot at Lunar South Pole Temperatures

The National Aeronautics and Space Administration (NASA) Artemis program plans to send astronauts to the lunar south pole, a region of the moon that is colder than previous lunar missions and low earth orbit operations. The spacesuit boots that will be used on these missions will be directly impacted by these extremely cold temperatures (down to ~50 K). To assess the performance of the Exploration Extravehicular Mobility Unit (xEMU) lunar boot in these extreme temperatures, the boot was tested at the Jet Propulsion Lab (JPL) in the Cryogenic Ice Transfer, Acquisition Development, and Excavation Laboratory (CITADEL) thermal vacuum (TVAC) chamber. This data was used to correlate thermal models to predict operational performance of the boots on the lunar south pole. This paper documents the data analysis, thermal boot model correlation, and operational predictions conducted using data from the xEMU TVAC test. Data from the test series was used to determine expected thermal conductances within the boot and between the boot and environment. These conductances were used to correlate a Thermal Desktop model of the xEMU boot across 10 different test points which varied external temperature, internal boot ventilation flowrate, and contact pressure. The correlated model was then used to predict operational performance in the lunar south pole. While the predictions indicate promising evidence for performance of the boots at the 100K test point, there is still substantial uncertainty in performance, particularly at the 48K test point. The results of this test series and model correlation stress the importance of improved testing for characterizing the expected thermal resistance between the outside of the boot and the lunar surface.

thermal analysis↗
NASA NTRS2026

Model Correlation and Thermal Analysis of xEMU Boot at Lunar South Pole Temperatures

The National Aeronautics and Space Administration (NASA) Artemis program plans to send astronauts to the lunar south pole, a region of the moon that is colder than previous lunar missions and low earth orbit operations. The spacesuit boots that will be used on these missions will be directly impacted by these extremely cold temperatures (down to ~50 K). To assess the performance of the Exploration Extravehicular Mobility Unit (xEMU) lunar boot in these extreme temperatures, the boot was tested at the Jet Propulsion Lab (JPL) in the Cryogenic Ice Transfer, Acquisition Development, and Excavation Laboratory (CITADEL) thermal vacuum (TVAC) chamber. This data was used to correlate thermal models to predict operational performance of the boots on the lunar south pole. This paper documents the data analysis, thermal boot model correlation, and operational predictions conducted using data from the xEMU TVAC test. Data from the test series was used to determine expected thermal conductances within the boot and between the boot and environment. These conductances were used to correlate a Thermal Desktop model of the xEMU boot across 10 different test points which varied external temperature, internal boot ventilation flowrate, and contact pressure. The correlated model was then used to predict operational performance in the lunar south pole. While the predictions indicate promising evidence for performance of the boots at the 100K test point, there is still substantial uncertainty in performance, particularly at the 48K test point. The results of this test series and model correlation stress the importance of improved testing for characterizing the expected thermal resistance between the outside of the boot and the lunar surface.

xEMU↗
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 were: to evaluate the risk lunar PSRs pose to advanced spacesuit boots, validate the xEMU lunar boot thermal model, and 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.

TVAC↗
NASA NTRS2026

Predicting Operational Performance of xEMU Boot at Lunar South Pole Temperatures using Thermal Desktop ®

The spacesuit boots that will be used on Artemis lunar south pole surface missions will be exposed to extremely cold temperatures (down to ~50 K). To assess the performance of the government’s Exploration Extravehicular Mobility Unit (xEMU) lunar boot in these permanently shadowed regions, testing was performed at the Jet Propulsion Lab (JPL) in the Cryogenic Ice Transfer, Acquisition Development, and Excavation Laboratory (CITADEL) thermal vacuum (TVAC) chamber. This paper documents the data analysis, thermal boot model correlation, and operational predictions conducted using data from the xEMU CITADEL TVAC test. Expected thermal conductances within the boot and between the boot and environment were calculated from test data, which was then used as an initial guess for conductances within a Thermal Desktop (TD) model. Correlation of the TD model using the internal SOLVER feature was performed across 10 different test points which varied external temperature, internal boot ventilation flowrate, and contact pressure. Operational performance at the lunar south pole was then predicted using results from the correlated model. While the predictions provide evidence for acceptable performance of the boots at the 100K environment test point, there is still substantial uncertainty in performance, especially at the 48K test point. This uncertainty is due in part to testing limitations such as contacting the foot to a hard metal plate rather than granular regolith, and model limitations such as the lack of a realistic foot model. These limitations and their impacts are addressed in detail in this paper. The results of this test series and model correlation underscore the importance of additional improved testing and modeling for characterizing the expected thermal resistance between the outside of the boot and the lunar surface.

Spacesuit↗
NASA NTRS1990

Requirements for extravehicular activities on the lunar and Martian surfaces

Basic design reference requirements pertinent to EVA equipment on lunar and martian surfaces are provided. Environmental factors affecting surface EVA are analyzed including gravity, dust, atmospheric conditions, thermal gradients, lightning conditions, and radiation effects, and activities associated with surface EVA are outlined. Environmental and activity effects on EVA equipment are assessed, and emphasis is placed on planetary surface portable life support systems (PLSS), suit development, protection from micrometeoroids, dust, and radiation, food and water supplies, and the extravehicular mobility-unit thermal-control system. Environmental and activity impacts on PLSS design are studied, with focus on base self-sufficiency and reduction in resupply logistics.

Brown, Mariann F.↗
NASA NTRS2018

Musculoskeletal Injuries in US Astronauts: Injury Prevention Strategies, Including Pre-Flight EVA Fitness Training, Return to Flight Following Injuries, and Post-Flight Reconditioning

Outline: Background; Terrestrial experience -Initial investigation into MSK (MusculoSKeletal) injuries -MSK Medicine Program -Training injuries -NBL (Neutral Buoyancy Laboratory) EMU (Extravehicular activity Mobility Unit) Work Hardening Program -Return to duty -Post-flight reconditioning program; Inflight musculoskeletal conditions; Lunar Surface Operations; Post-flight injuries.

Scheuring, Richard A.↗
NASA NTRS1983

The manned maneuvering unit flight controller arm

The Manned Maneuvering Unit (MMU) and its support equipment provide an extravehicular astronaut mobility, and the ability to work outside the confines of the Shuttle Orbiter payload bay. The MMU design requirements are based on the highly successful Skylab M-509 maneuvering unit. Design of the MMU was started as an R&D effort in April 1975 and Flight Hardware design was started in August 1979 to support a possible requirement for in-space inspection and repair of Orbiter thermal protection tiles. Subsequently, the qualification test and production activities were slowed, and the current projected earliest first flight is now STS-11 in January, 1984. The MMU propulsion subsystem provides complete redundancy with two identical "system". Each system contains a high pressure gaseous nitrogen tank, an isolation valve, a regulator, and twelve 1.7 lbf (7.5 N) thrusters. The thrusters are packaged to provide the crew member six-degree-of-freedom control in response to commands from translational and rotational hand controllers. This paper discusses the MMU control arm requirements, design, and developmental history.

Falkner, K. E.↗
NASA NTRS1982

Satellite services system analysis study, part 3

The background, ground rules and assumptions, individual design reference mission results and total user benefit projection for the economic benefit analysis are discussed. Radiation protection, extravehicular activity (EVA) operational pressure, mobility effects, tool/glove/effects, anthropometric definition, EVA lighting, and equipment turnaround for the advanced extravehicular maneuvering unit are also discussed.

Source record↗
NASA NTRS1995

First flight test results of the Simplified Aid For EVA Rescue (SAFER) propulsion unit

The Simplified Aid for EVA Rescue (SAFER) is a small, self-contained, propulsive-backpack system that provides free-flying mobility for an astronaut engaged in a space walk, also known as extravehicular activity (EVA.) SAFER contains no redundant systems and is intended for contingency use only. In essence, it is a small, simplified version of the Manned Maneuvering Unit (MMU) last flown aboard the Space Shuttle in 1985. The operational SAFER unit will only be used to return an adrift EVA astronaut to the spacecraft. Currently, if an EVA crew member inadvertently becomes separated from the Space Shuttle, the Orbiter will maneuver to within the crew member's reach envelope, allowing the astronaut to regain contact with the Orbiter. However, with the advent of operations aboard the Russian MIR Space Station and the International Space Station, the Space Shuttle will not be available to effect a timely rescue. Under these conditions, a SAFER unit would be worn by each EVA crew member. Flight test of the pre-production model of SAFER occurred in September 1994. The crew of Space Shuttle Mission STS-64 flew a 6.9 hour test flight which included performance, flying qualities, systems, and operational utility evaluations. We found that the unit offers adequate propellant and control authority to stabilize and enable the return of a tumbling/separating crew member. With certain modifications, production model of SAFER can provide self-rescue capability to a separated crew member. This paper will present the program background, explain the flight test results and provide some insight into the complex operations of flight test in space.

Meade, Carl J.↗
NASA NTRS1986

Regenerable non-venting thermal control subsystem for extravehicular activity

Routine and complex EVAs call for more effective heat rejection systems in order to maximize mission productivity; an optimum EVA mobility unit (EMU) thermal control subsystem must require no expendables and introduce no contaminants into the environment, while conforming to minimum size limits and allowing easy regeneration. Attention is presently given to two thermal control subsystems, one of which can be integrated with the existing Space Shuttle Orbiter EMU to provide a 3-hour nonventing heat rejection capability, while the other can furnish the entire heat rejection capability requirement for an 8-hour Space Station EVA.

Roebelen, George J.↗
NASA NTRS2023

Exploration Extra-Vehicular Mobility Unit (xEMU) Composite Hard Upper Torso (CHUT) Development

The xEMU is the Exploration Mobility Unity or space suit designed for microgravity (cislunar and low earth orbit (LEO)) and lunar surface operations. This suit design allows crewmembers to perform extravehicular exploration, science, construction, maintenance, and contingency operations while unattached to a vehicle for life support in pressure and thermal environments that exceed human capability. The xEMU provides life support, environmental protection, and communications capabilities to the EVA crewmember while allowing sufficient mobility and visibility to perform dexterous EVA tasks. The effort documented in this paper, addressed the design, analysis, manufacturing, full-scale test article testing and validation for a Composite Hard Upper Torso(CHUT)unit. Design and analysis of the CHUT was based on measured B-basis properties of the selected S-glass/epoxy composite, and established final geometry, composite layup and interface details that met requirements. A complete manufacturing and assembly protocol was established for the CHUT starting from composite layup in the tool, to final assembly of all interface metal hardware prior to delivery to NASA for suit integration. Full-scale CHUT test articles underwent static and fatigue pressure testing (2 lifetimes), impact testing at critical stress locations for tool drop/microgravity scenarios, followed by post-impact fatigue testing. Effect of manufacturing defects was evaluated by manufacturing a full-scale CHUT with 0.375”/0.5” defects at critical stress locations, followed by static and life-cycle fatigue testing. In all cases, the CHUT design met or exceeded mass, structural, interface and functional requirements. Two (2) complete CHUT articles were delivered to NASA for full-scale suit integration and testing.

spacesuit↗