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Inflatable softgoods are complex, multi-material system in which each layer performs a specific function. NASA is supporting the private sector in development and testing of inflatable softgoods architectures through public-private partnerships. Inflatable softgoods represent one structural material option for future habitation platforms.
To help guide NASA and industry in the development and certification of crewed softgoods structures, this document details the fundamental testing, data, and documents recommended for the evaluation of a softgoods inflatable designed for crewed occupation in a space environment. This is not a requirements document but supports NASA-imposed standards used for certification. This document is intended to support and guide the development of programmatic requirements to demonstrate a design has followed a systematic and comprehensive design, fabrication, and test program.
The Habitation Systems Development Office (HP40) at NASA Marshall Space Flight Center supports systems engineering, integration, and project management for next generation space habitats. The office is responsible for formulation activities for Lunar Surface Habitat and Mars Transit Habitat. HP40 also manages commercial partnerships for exploration habitat development. The Lunar Surface Habitat is intended to initially support a minimum of two crew on the lunar surface for an approximately 30-day mission, with the ability to accommodate four crew for short durations. The Mars Transit Habitat will transport four crew to and from Mars orbit on a potentially 1,200 day mission. Both concepts are envisioned to leverage inflatable softgoods as the primary structural material for the habitation portion of the architecture. Inflatable softgoods are a complex, multi-material system consisting of multiple layers which perform specific functions. A bladder layer (polymer) contains the habitat’s atmosphere. The bladder is indexed to a woven restraint layer, usually Kevlar or Vectran, which serves as the structural layer. The remaining outer layers are for micro-meteoroid orbital debris (MMOD) shielding, protection from atomic Oxygen (if the material system is to be deployed in low earth orbit), and thermal insulation. The primary advantage of inflatable softgoods is that they can offer a larger volume per unit mass relative to a rigid metal structure. Inflatable softgoods have a strong development heritage within NASA, beginning with work in the 1960s in partnership with Goodyear Aerospace and continuing with Johnson Space Center’s TransHab project in the 1990s . Some development efforts subsequently transitioned into the private sector to mature the material technology for flight applications, including human habitation. In August 2022, NASA published its guidelines for certification of crewed inflatable softgoods structures (JSC-67721). This document outlines a series of tests which will be needed to certify inflatable softgoods material systems for use in crewed mission applications. It includes burst testing at the subscale and full-scale to determine the ultimate burst pressure of the softgoods architecture. Creep (long term deformation of the material under stress) is a key failure mode which must be characterized. Creep testing at the component and module levels is also recommended to generate time to failure curves and verify that the inflatable system has a predicted operational life which exceeds mission parameters. ET (Test Engineering) at MSFC and HP40 have worked together to establish softgoods testing capabilities for the center. This includes the ability to conduct module level burst tests and creep tests. The poster will highlight these capabilities and provide examples of testing which has been performed to date by ET. NASA MSFC anticipates that these test capabilities will continue to offer critical support for companies pursuing inflatable softgoods for exploration applications (lunar surface habitation, Mars transit) as well as commercial low earth orbit platforms.
Overview of inflatable softgoods and their emerging role in enabling large, resilient space habitats and infrastructure. It highlights the advantages of inflatable systems, such as exceptional packing efficiency and scalable habitable volume, while also addressing challenges related to outfitting, complex material behavior, structural design, manufacturing precision, and testing limitations. Core architectural elements of crewed inflatable habitats are described, along with shell layer composition, structural interfaces, and examples of conceptual habitat configurations for transit, lunar, and surface applications. The presentation concludes by outlining key technology shortfalls, including structural health monitoring, ultra‑high‑strength materials, lifetime performance, and integration strategies, emphasizing the need for continued development to support future in‑space manufacturing and exploration missions.
Future NASA exploration plans call for lunar and Martian surface systems that form a base camp of multiple, pressurized elements. These discrete components, including habitats and pressurized rovers, require interoperability to meet the Artemis Accords and standard docking systems to physically connect elements together. A pressurized, articulating crew transfer tunnel can be used between a rover and habitat to enable shirt-sleeve transfer of crew and cargo, saving valuable crew time and resources. While transfer tunnels have been described in the past, this work details the design of a structural softgoods system that has compliant capability through a proposed docking range of motion. The inflatable softgoods design is based on a zero-hoop stress shape, known as a Taylor surface, that is stacked and truncated to form a unique and flexible configuration. Analytical, non-linear models have been developed to examine and predict the behavior of the structure, and material testing was used to determine the properties that were used in the model. Finally, a sub-scale test article was constructed using the baseline design and pressurized testing is in work. Additional full-scale testing is planned for future years to fully demonstrate the capability of the system.
Future NASA exploration plans call for lunar and Martian surface systems that form a base camp of multiple, pressurized elements. These discrete components, including habitats and pressurized rovers, require interoperability to meet the Artemis Accords and standard docking systems to physically connect elements together. A pressurized, articulating crew transfer tunnel can be used between a rover and habitat to enable shirt-sleeve transfer of crew and cargo, saving valuable crew time and resources. While transfer tunnels have been described in the past, this work details the design of a structural softgoods system that has compliant capability through a proposed docking range of motion. The inflatable softgoods design is based on a zero-hoop stress shape, known as a Taylor surface, that is stacked and truncated to form a unique and flexible configuration. Analytical, non-linear models have been developed to examine and predict the behavior of the structure, and material testing was used to determine the properties that were used in the model. Finally, a sub-scale test article was constructed using the baseline design and pressurized testing is in work. Additional full-scale testing is planned for future years to fully demonstrate the capability of the system.
Inflatable space structures have the potential to significantly reduce the required launch volume of large crewed pressure vessels for space exploration missions. Mass savings can also be achieved via the use of high specific strength softgoods materials, and the reduced design penalty from launching the structure in a densely packaged state. Inflatable softgoods structures have been investigated since the late 1950's, and several major development programs at NASA and in industry have helped advance the state-of-the-art in this technology area. This paper discusses the design, analysis, structural testing, and potential applications for inflatable softgoods structures. In particular, this paper will discuss the design of the multi-layer softgoods shell (inner layer, bladder, structural restraint layer, micrometeoroid orbital debris protection layers, thermal insulation layers, and atomic oxygen layer (for low earth orbit) and the results of material and module-level testing that has been conducted over the past two decades at NASA. Finally, the current utilization of expandable spacecraft structures is discussed, as well as potential future applications including airlocks and habitats on the Lunar Orbital Platform-Gateway, and the surface of the Moon and Mars.
The NASA TransHab project was a flight development program of a crewed inflatable habitat designed for in-space use. Through the course of the development, several novel technologies were developed and patented by NASA. One of these patents included information regarding a custom seam stitch that was used in the TransHab restraint layer design. As the patent protection has ended, the details of the custom seam stitch are being disclosed. The seam stitch developed during the TransHab program is known as the ‘tapered diamond stitch’ and includes both a ‘single’ and ‘double’ tapered diamond pattern for ‘end termination’ and ‘continuous’ webbing components respectively. It was designed for 1-in wide Kevlar webbings with load ratings of 6,000 lbf and 12,500 lbf. The stitch pattern was designed to gradually transfer load along the length of the seam using a tapered diamond geometry. The diamond stitch has been shown in tensile testing to provide greater than 85% load strength efficiency, compared to the pristine webbing.
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Space habitation is becoming more accessible and commercially available which is driving the development and testing of inflatable softgoods habitats that can be both lighter and more volume-efficient than heritage metallic pressure vessels. Photogrammetry test methods are used on new materials and larger inflatable softgood test articles to measure material displacement and strain during pressurization. A speckle pattern must be applied to the surface of interest for testing when using photogrammetry which is typically a very labor and time intensive process. Two methods were tested as options for a faster and more effective application to hand painting and temporary tattoos, which are the current application methods for the structural/restraint layer. One approach was to mix a plastic additive with a matte clear coat to create a speckle pattern that could be applied to the article. The second method uses a speckle paint gun to speckle the article after a white base coat is applied. Both methods adhered well to the Kevlar test sample materials and showed up well when examined with photogrammetry cameras. On the woven test samples the additive in a clear coat method could be applied evenly as was the paint gun method.
Space habitation is becoming more accessible and commercially available which is driving the development and testing of inflatable softgoods habitats that can be both lighter and more volume-efficient than heritage metallic pressure vessels. Photogrammetry test methods are used on new materials and larger inflatable softgood test articles to measure material displacement and strain during pressurization. A speckle pattern must be applied to the surface of interest for testing when using photogrammetry which is typically a very labor and time intensive process. Two methods were tested as options for a faster and more effective application to hand painting and temporary tattoos, which are the current application methods for the structural/restraint layer. One approach was to mix a plastic additive with a matte clear coat to create a speckle pattern that could be applied to the article. The second method uses a speckle paint gun to speckle the article after a white base coat is applied. Both methods adhered well to the Kevlar test sample materials and showed up well when examined with photogrammetry cameras. On the woven test samples the additive in a clear coat method could be applied evenly as was the paint gun method.
Space habitation is becoming more accessible and commercially available which is driving the development and testing of inflatable softgoods habitats that can be both lighter and more volume-efficient than heritage metallic pressure vessels. Photogrammetry test methods are used on new materials and larger inflatable softgood test articles to measure material displacement and strain during pressurization. A speckle pattern must be applied to the surface of interest for testing when using photogrammetry which is typically a very labor and time intensive process. Two methods were tested as options for a faster and more effective application to hand painting and temporary tattoos, which are the current application methods for the structural/restraint layer. One approach was to mix a plastic additive with a matte clear coat to create a speckle pattern that could be applied to the article. The second method uses a speckle paint gun to speckle the article after a white base coat is applied. Both methods adhered well to the Kevlar test sample materials and showed up well when examined with photogrammetry cameras. On the woven test samples the additive in a clear coat method could be applied evenly as was the paint gun method.
Habitat outfitting generally refers to the supplies and equipment (and installation thereof) which provide crew with a livable, safe environment during a mission and enable the performance of mission tasks. Outfitting will be needed on future missions for habitation to provide the crew with a livable and safe environment. Both softgoods inflatable habitats, which are packaged and deployed/inflated at the point of use, and constructed habitats, which may be manufactured using in situ resource-derived materials on a planetary surface, will require more outfitting than traditional habitation approaches using rigid metallic structures (such as the International Space Station), where many elements can launch pre-integrated. For softgoods inflatable habitats, it is anticipated that much of the outfitting would be performed by crew, while in constructed habitation scenarios outfitting may be done by robotic systems as part of precursor missions. This paper provides an overview of future planned habitats and outfitting needs, technology gaps related to outfitting, and current work under NASA’s habitat systems development, in-space manufacturing, and habitat construction portfolios related to this topic.
NASA’s Artemis campaign seeks to return humans to the moon and establish a sustained presence on the lunar surface. This session will emphasize how habitation capabilities on the moon and in cislunar space can potentially contribute to the sustainability objectives of Artemis. Habitable elements represent opportunities to enable longer duration stays, increase the number of crew members present, enhance science and utilization activities, drive technology development for future Mars exploration, perform analog missions, and fuel economic opportunities for US industry. Panelists include Paul Kessler (NASA Marshall Space Flight Center, deputy lead for lunar surface habitation); Andrew Choate (NASA Marshall Space Flight Center, Mars habitation lead); Krystofer Dudzinski (NASA Marshall Space Flight Center, a space architect within the MSFC Advanced Concepts Office); and Larry Toups (retired from NASA Johnson Space Center, currently an adjunct professor at University of Houston in space architecture). The panel is moderated by Tracie Prater (NASA Marshall Space Flight Center, Habitation Systems Development Office). The panel will begin with an overview of the history of habitation concepts and an academic perspective on general considerations in space habitat design (Larry Toups). Paul Kessler and Andrew Choate will introduce NASA’s principle of “architecting from the right” to help define objectives for Artemis missions, needs/characteristics, use cases, and functions (as published in the agency’s Architecture Definition Document) and provide perspective on how this principle informs habitation concept development work. NASA panelists will discuss key engineering challenges identified for developing, deploying, and operating habitable assets on the lunar surface and/or in deep space. These may include dust mitigation, outfitting of inflatable softgoods (for concepts which may use softgoods as a primary structural material), survival in lunar darkness, human health and performance considerations, maintenance/repair/sparing, and autonomy. These identified challenges represent risks for habitation systems development and relate closely to capability gaps identified by the agency. While the work of NASA Marshall Space Flight Center’s habitation development office is primarily focused on habitats which are launched from earth pre-integrated (referred to as Class I in the framework previously developed by NASA space architects Kennedy/Cohen) or launched from earth and deployed at the point of use (Class II), there is also extensive work in NASA, academia, and companies on constructed habitats, which would be built on a planetary surface using indigenous resources (Class III habitats). Panelist Krystopher Dudzinski will discuss potential evolutionary pathways from Class I and Class II habitats to Class III habitats, unique and common architectural challenges within each habitat class, and key gaps in implementing Class III habitats from an architectural perspective. NASA panelists and the moderator will also provide an overview of partnership opportunities and avenues for further engagement to advance habitation systems for the SpaceCom audience. NASA is currently developing notional concepts for a lunar surface habitat and Mars transit habitat, which will be discussed during this panel session and used as examples. These concepts represent options for habitation system design and are a point of departure. They do not represent a final plan or formal recommendation on the part of the agency. Based on the most recent analysis cycle, NASA’s lunar surface habitat (SH) concept nominally supports two crew members for 30 days, with the capacity to support four crew during a surge period where crew will swap between the SH and another surface asset, such as a pressurized rover. This example design has a metallic airlock for ingress/egress and the upper portion is an inflatable material system which serves as the habitation module. The notional interior of the habitat is a three-deck layout/configuration which supports all crew mission functions, including exercise, stowage, extravehicular activity (EVA), sleep, hygiene waste collection, maintenance and repair, and meal preparation. Under analysis assumptions for habitation, the Mars Transit Habitat (TH) concept would support four crew on an up to 1,200 day Mars mission. One option for the concept is to initially dock Transit Habitat at Gateway, where it can be used to increase the duration of crew stays in cislunar space and perform shakedown and analog missions prior to a Mars departure. One challenge in longer duration missions which involve both surface exploration and transit is understanding crew adaptation when transitioning between partial gravity and microgravity environments. TH at Gateway offers an opportunity to study this transition and in doing so reduce risks associated with future Mars exploration. Like lunar SH, the most recent analysis cycle concept of a Mars TH is a hybrid structure design, with a metallic section supporting EVAs, axial/radial docking, and Safe Haven capabilities, and an inflatable softgoods structure for the primary habitation function. Interior layouts to optimize crew usability and livability are currently under trade. The panel will include presentation material, but also seeks to engage the audience in a highly interactive conversation regarding the potential role for habitation in future exploration initiatives. Potential topics for discussion include the influence of the crew experience on habitation systems design and livability/usability considerations, the benefits of space habitation development in terrestrial applications, and challenges and opportunities in “feeding forward” lunar surface habitation systems development to Mars exploration.
This paper details the results of an initial study to develop a certification plan for human-rated inflatable space structures, including guidelines for qualification testing. Habitable softgoods inflatables are multi-layered shell structures that use high-strength webbing, cordage and broadcloth fabric to carry the skin loads of a variety of volumetric shapes and structural architectures. The primary objectives of this study are to define the key parameters that affect these structures and propose a statistically robust approach to defining safety and knockdown factors based on test and analysis. Current NASA standards for habitable inflatable space structures use a factor of safety of 4, which was inherited from airship design criteria. An updated approach to defining a design factor, taking into account material strength variability, load variability in the article, number of test samples, and damage and degradation effects is specified. Accurate analytical modeling of these structures is hindered by the difficulty of obtaining accurate and consistent material data due to load-history- dependent, nonlinear load versus strain behavior. A building block approach to certification is detailed that uses stochastic modeling and statistical test design and analysis to address the unique challenges these high-strength softgoods structures present. Human-rated inflatable modules are a transformative capability for launching much larger habitable volumes into space than is possible with rigid shell structures. This research aims to provide the framework for certifying these structures for future human space exploration missions.
Crewed inflatable softgoods structures can significantly reduce launch volume for habitable pressure vessels. To ensure the operational safety of these structures, NASA has developed an extensive testing program to evaluate the structural capability on ground test articles. This paper will discuss a current challenge faced by test engineers evaluating the strain of large-scale inflatable space structures during ground testing. Namely, the difficulty that arises using monochrome digital image correlation (DIC) to evaluate bi-axial strain for woven-webbing restraint layers. This report provides insight into a novel method of photogrammetry using red-green-blue (RGB) filtering in conjunction with DIC to evaluate the strain in each direction on a test article experiencing bi-directional strain. To evaluate this concept, a uniaxial tensile test was performed that represented a biaxial woven architecture using orthogonally interfaced straps. The resulting analysis demonstrates promise for this novel approach for isolating a specific region and direction of strain, reducing the effects of straps not in the area of interest, while allowing for a larger region of analysis. Moreover, it was shown that the application of a white basecoat prior to applying photogrammetry patterns significantly reduced data loss while performing RGB filtered DIC.
Large diameter inflatable habitat solutions are hypothesized to have an advantage over traditional metallic habitats of equal volume and functional requirements in terms of minimizing mass. A fair and comprehensive trade of metallic primary structure versus inflatable softgoods primary structure for a Mars Transit Habitat was conducted by The Boeing Company under the NASA Next Space Technologies for Exploration Partnerships-2 (NextSTEP-2)Appendix A contract in order to determine the minimum mass option from a system level. A Mars Transit Habitat is a major system mass driver because small increases in the mass can create large mass changes in the propulsive stage, adding complexity and cost to the mission. Three different vehicle configurations were traded using a fixed volume constraint and the same Ground Rules and Assumptions(GR&A)provided by NASA. The configurations were 1) 5.5 m diameter metallic habitat, 2) 7.0 m diameter metallic habitat, and 3) 7.63 m diameter inflatable habitat. In order to complete the trade, each configuration was analyzed and sized, but a system level approach had to be taken to ensure other aspects and subsystems besides the structure were captured. The primary functions (i.e. restraint layer, bladder, multilayer insulation [MLI], micro-meteoroid orbital debris [MMOD]) and strength advantages of softgoods are well understood, but there were other system level impacts that were discovered or addressed that are unique to softgoods. For the metallic structure, a modern and mass optimal material and manufacturing process was adopted to ensure the lightest weight options were evaluated. Two different aluminium lithium structures were evaluated, a longer length 5.5 m diameter and a shorter length 7 m diameter structure. The trade demonstrates that each configuration is feasible and close to the target dry mass for the Mars Transit Habitat Trans-Martian Injection burn. System level mass was the primary consideration, but since the three concepts were close in total mass, a clear winner did not arise. Secondary factors were evaluated such as architecture habitability (human factors), development considerations, on-orbit activation and outfitting, extensibility to other applications, and configuration flexibility. The aggregation of the lowest mass, most benefits, and fewest challenges resulted in the 5.5m diameter metallic configuration being the most favorable.
This report discusses testing of a bi-axial woven panel consisting of high-strength webbings that represent a portion of the structural restraint layer of an inflatable space structure. Inflatable softgoods vessels are being researched for human space missions as possible habitats, airlocks and tunnel elements. Understanding the complex behavior of the softgoods restraint layer and maturing finite element analysis capabilities to model these structures is critical to their successful implementation. The primary goal of this research is to study the load-up and load distribution in a weave of webbings, before and after the loss of tension in one of the webbings. In addition, a key objective is to evaluate the ability to convert strains measured via photogrammetry using digital image correlation to loads in the weave. The report gives an introduction and objectives for the test program and a description of the test fixture, setup and procedure. This is followed by a section focusing on the test data and associated discussion. To streamline presentation of the data, one focus case is detailed in the main text. (Comprehensive data set can be found in Appendix A for the three remaining test cases.) In addition to the load and time histories for one case, summary charts and tables that incorporate data from all four test cases are provided. The concluding remarks include major findings, lessons learned and recommendations for future work. Appendix B provides complementary full-field strain results when considering the existing woven webbing data as a fabric. These types of results could inform models intended for global representation. Appendix C contains a description from a series of exploratory instrumented hammer tap tests and results on the weave. These tests describe an area of research for the biaxial test fixture beyond the current testing studying the propagation and detection of vibrations in a tensioned weave that has applications in impact and damage detection.