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45th International Conference on Environmental Systems ICES-2015-205 12-16 July 2015, Bellevue, Washington Design and Testing of Advanced Space Suit Hybrid Upper Torso Greg Muller 1 , and David Graziosi 2 ILC Dover, Houston, Texas 77058 As future missions dictate better mobility, material enhancements, and new technologies, suit design must be iterated to stay ahead of the curve. Over the span of several enhancement projects focused on improving the form, fit, and function of the upper torso design, ILC Dover has investigated state of the art technologies, explored new manufacturing techniques and built prototypes for the purpose of testing these new concepts. Building upon the heritage of the legacy EMU upper torso the hybrid upper torso is a combination of the adaptability of a Soft Upper Torso (SUT) and the rigidity of a Hard Upper Torso (HUT). The hybrid takes the soft restraint and bladder system from a SUT and attaches a hard metal support structure to make the neck, scye, rear door frame, and BSC position rigid using a light weight frame. On the EMU space suit the difference between a medium and large hard upper torso is a one inch difference in scye breadth. The design, tooling, and manufacturing costs required for delivering multiple sized hard upper torsos is eliminated with the hybrid upper torso. The hybrid upper torso does not require a fixed scye location but instead has detachable sizing panels that allow the scye bearing placement to be manipulated, this allows for what would be multiple sizes of hard upper torso to be built into a single hybrid upper torso. This concept could even allow for custom panels to be made for individuals that may need a non-standard scye angle, or a mission specific scye angle. These enhancements improve the sizing capability and can reduce the potential for a shoulder injury due to a poor fit in the suit. Because the Hybrid upper torso is designed to meet a 8.3psid operational pressure the hybrid upper torso is extensible to LEO or planetary missions. This paper will describe several technology advancements ILC is developing to improve space suit upper torso design. Nomenclature AM = Additive Manufacturing BSC = Body Seal Closure CSSS = Constellation Space Suit System DCM = Display and Control Module DTO = Detailed Test Objective DMLS = Direct Metal Laser Sintering EBM = Electron Beam Melting EMU = Extravehicular Mobility Unit ESOC = EVA Space Operations Contract EVA = Extravehicular Activity FAR = Fabric Attachment Ring FEA = Finite Element Analysis FDM = Fused Deposition Modeling FOS = Factor of Safety GFE = Government Furnished Equipment HIP = Hot Isostatic Pressing HUT = Hard Upper Torso HyUT = Hybrid Upper Torso 1 Design Engineer, Advanced Suit Product Group, 2200 Space Park Dr. Ste 110, Houston, TX 77058 2 Chief Engineer, Advanced Suit Product Group, 2200 Space Park Dr. Ste 110, Houston, TX 77058, AIAA Member

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Page 1: Design and Testing of Advanced Space Suit Hybrid Upper Torso · Advanced Space Suit Hybrid Upper Torso Greg Muller1, and David Graziosi2 ILC Dover, Houston, Texas 77058 ... hand over

45th International Conference on Environmental Systems ICES-2015-205 12-16 July 2015, Bellevue, Washington

Design and Testing of

Advanced Space Suit Hybrid Upper Torso

Greg Muller1, and David Graziosi

2

ILC Dover, Houston, Texas 77058

As future missions dictate better mobility, material enhancements, and new technologies,

suit design must be iterated to stay ahead of the curve. Over the span of several

enhancement projects focused on improving the form, fit, and function of the upper torso

design, ILC Dover has investigated state of the art technologies, explored new

manufacturing techniques and built prototypes for the purpose of testing these new

concepts. Building upon the heritage of the legacy EMU upper torso the hybrid upper torso

is a combination of the adaptability of a Soft Upper Torso (SUT) and the rigidity of a Hard

Upper Torso (HUT). The hybrid takes the soft restraint and bladder system from a SUT and

attaches a hard metal support structure to make the neck, scye, rear door frame, and BSC

position rigid using a light weight frame. On the EMU space suit the difference between a

medium and large hard upper torso is a one inch difference in scye breadth. The design,

tooling, and manufacturing costs required for delivering multiple sized hard upper torsos is

eliminated with the hybrid upper torso. The hybrid upper torso does not require a fixed scye

location but instead has detachable sizing panels that allow the scye bearing placement to be

manipulated, this allows for what would be multiple sizes of hard upper torso to be built into

a single hybrid upper torso. This concept could even allow for custom panels to be made for

individuals that may need a non-standard scye angle, or a mission specific scye angle. These

enhancements improve the sizing capability and can reduce the potential for a shoulder

injury due to a poor fit in the suit. Because the Hybrid upper torso is designed to meet a

8.3psid operational pressure the hybrid upper torso is extensible to LEO or planetary

missions. This paper will describe several technology advancements ILC is developing to

improve space suit upper torso design.

Nomenclature

AM = Additive Manufacturing

BSC = Body Seal Closure

CSSS = Constellation Space Suit System

DCM = Display and Control Module

DTO = Detailed Test Objective

DMLS = Direct Metal Laser Sintering

EBM = Electron Beam Melting

EMU = Extravehicular Mobility Unit

ESOC = EVA Space Operations Contract

EVA = Extravehicular Activity

FAR = Fabric Attachment Ring

FEA = Finite Element Analysis

FDM = Fused Deposition Modeling

FOS = Factor of Safety

GFE = Government Furnished Equipment

HIP = Hot Isostatic Pressing

HUT = Hard Upper Torso

HyUT = Hybrid Upper Torso

1 Design Engineer, Advanced Suit Product Group, 2200 Space Park Dr. Ste 110, Houston, TX 77058 2 Chief Engineer, Advanced Suit Product Group, 2200 Space Park Dr. Ste 110, Houston, TX 77058, AIAA Member

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JSC = Johnson Space Center

LEO = Low Earth Orbit

LTA = Lower Torso Assembly

MSFC = Marshall Space Flight Center

NASA = National Aeronautics and Space Administration

NRA = NASA Research Announcement

Nd:YAG = Neodymium-doped Yttrium Aluminum Garnet

PLSS = Portable Life Support System

PSID = Pounds per Square Inch Differential

PXS = Prototype Exploration Suit

QD = Quick Disconnect

ROM = Range of Motion

RV = Relief Valve

SAFER = Simplified Aid for EVA Rescue

SSA = Space Suit Assembly

SUT = Soft Upper Torso

SLM = Selective Laser Melting

I. Introduction

HE hybrid upper torso is the advancement in space suit technology that has been needed for many years. A suit

that fits a person well is essential for being able to effectively perform tasks and is equally critical for helping

reduce the risk of injuring a crew member. The aging architecture of the EMU and a mission that is yet to be

decided, NASA needs an EVA space suit that can replace the capabilities of the EMU on ISS, but can also be used

in future missions when an objective is chosen. Because of the versatility it has, the hybrid upper torso has the

potential to be in that suit. For the new platform a resizable upper torso is needed to accomplish fitting the 5th%

female to 95th% male percentile crew population with as few upper torso assemblies as possible. The hybrid upper

torso would provide future astronauts with a more comfortable upper torso system, fitting a broader population with

fewer sizes and improvement to mobility.

T

Figure 1. Hybrid Upper Torso

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II. Design

ILC Dover Inc. has developed several sizable SUT systems over the years including the Nastic SUT. In 2004

ILC was awarded a three-year NRA grant for the development of innovative spacesuit pressure garment technology

that will enable safer, more reliable, and effective human exploration of the space frontier. The research focused on

the development of a high performance mobility/sizing actuation system for a spacesuit SUT pressure garment. This

technology has application in two areas the first was repositioning the scye bearings to improve specific joint motion

i.e. hammering, hand over hand translation, etc., and the second as a suit sizing mechanism to allow easier suit entry

and more accurate suit fit with fewer torso sizes than the existing EMU.

Research from 2004-2007 was divided into three phases. In phases 1 and 2 SUT actuation technologies were

developed and evaluated. This research involved developing a method of predicting and achieving sizing of a SUT

to meet these applications. This included a system requirement study, actuation study, electronic textile control

study, waist-entry and rear-entry SUT modeling and sizing analysis. In the final phase, a field of previously selected

actuation methods was narrowed to one active, pneumatically driven system (Nastic), and one passive, cable driven

system. These systems were developed into fully functioning prototypes which were outfitted to a table top SUT

mock-up which was later integrated into a full suit and tested. Both of these systems were shown to be successful in

positioning the SUT shoulder joint interface angles in a designated location and holding there until task completion.

The Nastic SUT is shown in Figure 2. The control mechanisms used for both the active and passive system was also

modeled and developed. The final phase was concluded by

collecting video of a manned demonstration of two of the sizing

systems in operation.1 These were successful prototypes but used

high pressure air to pneumatically actuate upper torso sizing.

A. REI Hybrid

In 2012 ILC began efforts to design a sizeable upper torso

assembly that didn’t require the power actuated sizing of high

pressure air. Instead the design would use metal inserts to control

the scye placement. ILC’s first design prototype was made on the

Rear Entry I-Suit platform in 2013. The REI Hybrid prototype

served two purposes the first was to develop a way of attaching the

sizing inserts that would provide the adaptability desired for the

scye bearing placement. The second objective was an examination

of if and how the components could physically be assembled. In

SUT assembly there is a specific order that the hardware must be

assembled for access to screw heads for installation and torquing.

When adding the hybrid brackets to the mix it was unclear if it

would just make assembly more difficult or if it would be possible

at all. The REI Hybrid was made of FDM polycarbonate it was non-

pressurisable but showed both that the SUT could be assembled and

the attachment methods showed promise.

Figure 3. REI Platform Hybrid Mockup.

12”

Figure 2. Sizing of Nastic Cell SUT.

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B. Z-1 Hybrid

In the second half of 2013 ILC investigated manufacturing the Hybrid

components for a pressurizable prototype using several types of rapid

prototyping. Using the Z-1 soft upper torso as the platform for the study

ILC developed a hybrid system model. The Z-1 suit has design heritage in

the REI suit. The Z-1 has multiple interface locations similar to REI that

allowed ILC’s hybrid system to be retro-fit onto the suit.

ILC looked at AM as a means of manufacturing components for this

hybrid system. AM was appealing because of the potential geometric

freedoms, coupled with its small lot size production efficiency. It was

believed AM provided a potential opportunity to effectively produce

custom components, and therefore enhance the quality of fit for each suit

subject. The perceived benefit of additively manufacturing is having the

capability of growing the inserts quicker and cheaper than traditional

machining. Being able to manufacture complex shapes with reduced touch

labor made AM worth investigating. ILC explored two AM technology

solutions for fabricating components for the Hybrid Upper Torso.

• Electron Beam Melting (EBM): A direct-metal AM process, this technology uses an electron beam energy source to selectively melt Ti6Al4 powder in a layer wise fashion.

• Selective Laser Melting (SLM): A direct-metal AM process, this technology uses an Nd:YAG laser to selectively melt Ti6Al4 powder in a layer wise fashion.

The two AM processes were traded against 5-axis machining.

During ILC’s study of the AM options advice was sought from NASA MSFC’s manufacturing technology

experts. MSFC is in the preliminary stages of developing

a document called “Engineering and Quality Guidelines

for Parts Fabricated by Selective Laser Melting.”3 Though

yet unpublished the document outlines how parts

manufactured with AM need to be tested based on

criticality. ILC used the MSFC document to guide the

sample testing specifically for the critical sizing inserts in

this design.

The first AM process that was looked at was SLM

commercially called DMLS. ILC elected to manufacture

only one component in SLM due to the cost and available

budget on the project. During manufacture the

manufacturer experienced a power-outage and the build stopped mid process. During the recovery from the power-

outage the manufacturer discovered that had the build completed the part would have been un-usable due to extreme

warp (Figure 6). Some amount of warp is normal in SLM but warping in the manner seen would prevent the sizing

panels from interfacing with the brackets properly. The manufacturer determined that they did not have the

capability to manufacture this size and shape part with the necessary precision.

EBM components were manufactured by Marshall Space Flight Center. Within NASA, MSFC is the center of

excellence for AM manufacturing. Figure 5 shows the successfully built sizing panels. Unlike SLM, there was no

noticeable warping in the EBM build. The EBM

however has a rough finish directly from the

machine that builds the parts. When touched to a

piece of restraint Dacron, the Dacron immediately

is hooked or cut by the rough surface. A complete

surface finishing operation would have to be done

to the completed components to prevent damage

3 The MSFC document provides guidelines that explain the number of test coupons needed to be grown alongside

the final part to verify the integrity of the additive build. Tensile and fatigue tests evaluate surface finish impacts,

and help define the appropriate finishing operations. Evaluations are also made to effectiveness of performing a Hot

Isostatic Pressing (HIP) cycle to the finished part to remove porosity, heal micro-fissures, reduce build-induced

residual stresses, and homogenize the microstructure. All of these testing methods and procedures could and are

research topics individually and are not the focus of this paper.

Figure 4. Failed Build of SLM Sizing Panel.

Figure 6. Warp in SLM Panel.

Figure 5. EBM Sizing Panels.

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Figure 8. Alignment and misalignment

caused by shrinkage.

to the restraint layer in the application desired for the hybrid upper torso.

It was also observed that the EBM components are 1-2% smaller than the model they were manufactured from;

this is similar to what would be expected in a casting operation but was not expected in the AM process. This may

be the highest tolerance that the EBM machine can achieve and this is accumulated error across the piece. Figure 8

shows how the sizing panel is aligned at one end of the bracket but misalignment on the other end of the bracket. It

would have been highly desirable to be able to grow the brackets using a metal AM method but during this study it

was concluded that AM is not capable of providing an acceptable part for this specific application.

Traditional 5-Axis machining has more than adequate capability to manufacture the components for a hybrid

upper torso. Traditional manufacturing has also shown to have as good or better lead time and lower cost when

compared to the AM methods. Traditional manufacturing from a solid plate material does not require additional test

samples to be manufactured and tested to show its structural integrity. Future developments in AM could provide a

viable option as the technology matures, AM is not practical in this application at this time.

Using the manufacturing data gathered, ILC fabricated a prototype hybrid upper torso assembly for the Z-1 suit

using traditional methods. ILC begin with the Z-1 soft restraint and bladder design and added the open iso grid

structure that allows scye bearing manipulation using sizing inserts. Position of the neck ring and waist ring relative

to the back door are fixed through the iso grid brackets. ILC was able to design a system that retrofit to all of the

existing Z-1 hardware. ILC manufactured two sizes of sizing inserts, one that locates the scye bearing in the same

position as the present Z-1 configuration, and one size that moved the scye breadth in one inch smaller. The position

and angles for the helmet, rear door, and waist are the same as Z-

1. Even in the nominal configuration the hybrid provides better

placement of the scye bearings improving the mobility for the

suit subjects. Maintining an exact angle placement of scye

bearings using only softgoods can be difficult as is shown in

Figure 7. Both configurations are equivalent but the softgoods-

only version let the scye bearings relax to a neutral position that

is not the exact angle designed, the hybrid holds the angle

because of the hardware.

C. HyUT

Following the Z-1 demonstration the decision was made to pursue a completely new configuration for the

hybrid. Rather than making compromises to fit existing hardware, a new platform for the design would best show its

abilities. For the new platform a resizable upper torso was wanted to accomplish fitting the 5th to 95

th percentile

4

crew population with as few upper torso assemblies as possible. ILC has done studies in the past for hard and soft

upper torso suit architectures to determine the number of upper torsos needed to properly fit 5th% female to 95

th%

male. The results consistently show that five to seven differently sized upper torsos would be required.2 The EMU

program shows the implementation of such a wide range of UTA sizes. The hybrid upper torso is will accommodate

4 ANSUR 88 data 5th to 95th percentile chest breadth is 9.86” – 14.44”. Chest breadth is close to the Q-distance

typically.

Figure 7. Z-1 Nominal configuration (left) and equivalent hybrid configuration (right).

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the same and greater range with only two upper torso cores. Using

the two cores the hybrid could have many sizes through the

interchange of the scye sizing panels.

At this juncture it is important to understand the Q-point in

space suit design. The Q-point is the intersection of the center

axis and the rear plane of the scye bearing. The spacing between

the left Q-point and the right Q-point is the Q-distance. The Table

1 shows the two hybrid cores as well as the Q-distance

capabilities of other UTA designs. With the HyUT any desired

sizing increment can be made for each of the cores bounded by

the limits shown. The exact anthropometry of the sizes with the

scye width adjustability remains to be investigated. However a

nominal upper lower and middle of the sizing ranges has been

designed. If this system was implemented using EMU hardware

there would potentially be a rearrangement of sizes and/or new

softgoods configurations using the existing hardware brackets and

disconnects.

After further development of the new hybrid architecture it

was noted that with smaller Q-distances the helmet disconnect

intersected the shoulder. A two helmet system consisting of an 11.5”

hemisphere for the small core and 13” hemisphere for the large core

was the initial concept. Even on some of the larger Q-distances there

was concern that the neck ring would impact arm mobility. The

helmet shape posed a problem, ILC examined the size and shape of

the helmet and the design options available. The trade looked at the

helmet shape in conjunction with the overall sizing scheme of the suit.

After examining the helmet shapes and relative placement to the scye

bearings development of an oval/elliptical shaped helmet with an

inner major axis of 13” and inner minor axis of 11” was recommended

for both core sizes. The down selection to a single helmet size reduced

sizing complexity and the commonality of the helmet will be

beneficial to any future logistics. The elliptical helmet enables one

helmet to work on both sizes. The small torso with the elliptical

helmet model showed adequate clearance near the neck ring for

sizing. The concern of impaired mobility with the hemisphere helmets

also was alleviated.

FEA was performed on the models of the hybrid as the design was

progressing. Analysis was performed to verify the proof of concept

would take the scye plug loads5 and man loads

6. There was still

opportunity to integrate the feedback from the results of the FEA as an

iteration of the design. Simulation showed that a large amount of the

plug load is carried into the chest plate. As an example in the first

round of FEA the chest plate load location overhung the shape of the

clamp ring as shown in Figure 10. The design was improved and

HyUT clamping ring design had the lip removed in this area.

Removing the lip then there was ability to eliminate the notch cut out

of the base of the front breast plate increasing the contact area for the

preloaded fasteners. Much of the feedback from this analysis has been

incorporated into the HyUT design already. The neck ring has been

redesigned and the BSC and clamp ring have been redesigned

eliminating the notch and integrating the countersink into the bracket

improving preload contact forces. The analysis that has been done

5 Force from air pressure. 6 Force applied by suit subject.

UTA Size Q Dist

EMU Planar Small 11.50

EMU Planar Medium 11.80

EMU Planar Large 13.00

EMU Planar XL 14.00

EMU Pivoted Small 10.28

EMU Pivoted Medium 10.77

EMU Pivoted Large 11.90

EMU Pivoted XL 12.90

Mark III Medium 12.00

Z-1 Large 14.80

HyUT Small Core 9.75-11.75

HyUT Large Core 12.00-14.00

Table 1. Space Suit Q-distance Capabilities.

Figure 9. HyUT Mockup with EMU LTA.

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leads ILC to believe that the HyUT is capable moving forward.

The scye carrier on the hybrid upper torso is larger than the

EMU. The scye bearing was an area that several studies have

suggested contributed to shoulder injury.7 The same studies

indicated that a larger scye opening would help reduce injury.

Larger volume around the shoulders is only part of the solution

ILC is offering for shoulder injury. Even with a larger scye

bearing the hybrid is able to achieve the smaller Q-distance sizes.

The larger scye bearing through the use of an insert adapter will

allow for interfacing with two options of an upper arm. If desied

through the use of an insert the upper arm assembly and scye

bearing on the EMU could be utilized in the hybrid upper torso.

The EMU upper arm was designed for only a 4.3psid operational pressure. The EMU upper arm is able to be

pressurized to 8.3psid however its mobility performance is significantly degraded requiring more physical exertion

of the subject to use. For 8.3psid operations the upper arm could be upgraded to the ILC rolling convolute. The scye

bearing on the hybrid upper torso is 1.2” in diameter larger then then existing EMU scye bearing. The larger size

allows for less shoulder contact when used with the rolling convolute shoulder. To interface with an EMU arm an

adapter would be used. Both upper arm assembly options will interface to the existing EMU lower arm FAR and

will continue the use of the Phase VI glove. The lower arm assembly has been shown to operate effectively at

8.3psid.

All of the design improvements were combined into the

prototype HyUT. The HyUT features:

• Elliptical helmet bubble,

• Upper torso inserts that can be installed and removed for resizing by hand, without the use of tools,

• Scye and shoulder assemblies, also needing no tools to remove and install.

• H-Suit/MK III style rear entry3 and EMU style waist entry.

ILC also examined PLSS options to which the hybrid upper

torso could potentially interface. The existing EMU PLSS

could be used, however as servicing the old PLSS is becoming

more difficult it is believed that one of the new PLSS concepts

will be pursued for design effort for interface. Any of the PLSS

options being designed by different groups could interface to

the hybrid upper torso throgh small configuration changes.

Included with the life support options the hybrid upper torso

could interface to the SAFER.

III. Testing

Three phases of testing with the hybrid upper torso assembly have been done. The first stage of testing was the

Z-1 proof of concept, mentioned earlier, using Z-1 hardware retrofit with hybrid components. During the Z-1 proof

of concept three subjects with experience in the Z-1 suit evaluated the hybrid configuration. Drawing from the

subject’s experience in Z-1 nominal hardware, subjects responded to questions related to the size, fit, and feel of the

hybrid configuration. Additionally suited subjects were asked to evaluate their reach to the hatch release mechanism.

7Shoulder injury studies include: “EMU Shoulder Injury Tiger Team Report”, NASA/TM-2003-212058, D.

Williams and B. Johnson

“NASA Shoulder Injury TIM Recommendations”,03-DEC-2012

“Musculoskeletal Injuries and Minor Trauma in Space: Incidence and Injury Mechanisms in U.S. Astronauts”,

Aviation, Space and Environmental Medicine, Vol. 80, No. 2, February 2009, R. Scheuring and others

“Shoulder Injuries in US Astronauts Related to EVA Suit Design” (presentation), September 14, 2012, R.A.

Scheuring 3-9769

Figure 10. FEA improvement example.

Figure 11. Hybrid with EMU DCM and

PLSS.

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The reach to the hatch release was an action that only a few people had successfully been able to do, none of whom

were in this group of three. The primary goal of the Z-1 evaluation was to show the feasibility of the hybrid sizing

design, not to gain any specific reach or range of motion data. There were two sizes of inserts for the Z-1 during the

fit check series the sizing panels were swapped out 4 times. One manufacturing error was noted on a particular rear

sizing panel was machined to a slightly thicker dimension, resulting in binding when attempting to remove it, a light

tap with a rubber mallet would loosen it up for removal. Additionally the scye interface was sensitive to off plane

removal due to tight clearance holes. Future renditions of these interfaces have had the manufacturing tolerances

adjusted to prevent tight clearances. The large size insert was designed to match the normal Z-1 Q-distance (see

Figure 7) subjects confirmed the large size felt “familiar” as the normal Z-1 configuration. Immediately following

the large size tests inserts were swapped to the small size. The small size had a one inch smaller Q-distance. The

small size subjects reported feeling more indexed into the gloves. Subjects preferred the small size due to the

indexing into the gloves. Because there is only one normal size of the Z-1 the subjects did not have sizing options.

The subjects would fall into this slightly smaller size if it was a regular option. Across both sizes subjects reported

more chest contact around the scye, as being different, but not uncomfortable from the normal Z-1. The change in

controlled scye angle could make this difference.

All subjects noted better reach to the release

mechanism with the hybrid configuration. Subjects

noted even greater reach with the small size over

the large. For the three subjects in this test the

small size was the better fit. For fhe Z-1 hybrid

testing series the restraint under each arm billowed

out as shown in Figure 12 causing some

interference with reach down and back, there was

also some billowing that interfered with the release

mechanism itself though not the reach in that area.

The restraint and bladder had been deliberately

oversized for the Z-1 test. It has now been shown

that optimizing the restraint and bladder

configuration will prevent billowing from

occurring. At the time, schedule constraints

prevented an iteration to optimize restraint and bladder in the time frame for the testing on the Z-1. Testing also

showed that many of the brackets could and should be integrated together to improve performance. The Z-1 hybrid

was a retrofit system and integration of the brackets would be forward work.

The second phase of the testing was both optimizing and burst testing the restraint and bladder. The fabric used

to make EMU SSA restraints has been discontinued by the manufacture and a new material in in the process of

being identified. The leading material candidate was used for a burst test of the SUT. The SUT serves as the

secondary restraint in the hybrid upper torso. The test was run prior to the final material down select. The leading

material and presumed winner was chosen in

attempt to make the prototype the final material

choice. Material testing is still ongoing. The

material used for this test was a spectra fabric.

The SUT was of a single wall construction that

was first proof tested with air at 15.2 ± .5 psid

for 5 minutes without any structural damage.

After passing a structural test the SUT was

filled with water and all the air bubbles

removed. Pressure was slowly increased until

failure occurred at approximately 20 psig.

Failure mode when test was terminated was at a

join seam where stitching failed first followed

by restraint fabric ripping on either side. The

bladder material stretched enough that the

bladder did not experience any failures. Prior

tests with a double wall SUT and legacy EMU

materials, now discontinued, have resulted in

failure pressures in the 50-60psid ranges. This

Figure 12. Billowing of excess restraint.

Figure 13. Hybrid SUT burst test.

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burst test will be performed again once the final replacement material choice has been made. As these materials have

the capability of greater burst pressure.

The third phase of hybrid testing that has taken place has been using the HyUT. As of this writing five subjects

have done testing in the HyUT. Two subjects in the testing have had no EMU experience. Both of the inexperienced

subjects were immediately able to manipulate the shoulders of the suit. The manipulation known in ILC as “rolling

the shoulders”, where the arm bearing and the scye bearing rotate a complete 360 degrees, only moving the

shoulders. This action has been an indication in the EMU of both good sizing and good experience with the

programming of the suit. All of the subjects have been able to accomplish and repeatedly reach each request

throughout testing. All subjects, including the smallest, have been able to reach the hatch release mechanism (Figure

14) and reach for the area the SAFER controller would be. Figure 15 shows the overhead reach of the HyUT. The

potential placements of DCM and RV valves were evaluated in this testing series as well. Location and routing of

the PLSS hoses have been looked at conceptually.

IV. Conclusion

The evolution and development of the next EVA space suit is an ongoing task. Because of it’s sizing versatility

the hybrid upper torso has the potential to be the advancement in space suit technology that has been needed for

many years. Forward work includes building a new and improved hybrid upper torso for the PXS suit being built for

the CSSS contract. ILC will combine many of the improvements identified through the testing described in this

paper. The purpose is to refine the manufacturability of the designs for upper as well as lower torso and evaluate

how they combine together on the same platform. Torque and ROM studies will be conducted to gather data on the

mobility enhancements. Further integration with PLSS design and DCM design will be shown. This research

focuses on an effort to push the state of the art in space suit upper torso design. Both to replace and renew the

capabilities of the EMU on ISS, but also future missions.

Acknowledgments

The authors would like to thank all those at ILC Dover both in Houston and Delaware and NASA JSC & MSFC

that aided in the design and testing of these prototypes and suits.

References

1Jones, R., Graziosi, D., Splawn, W., Ferl, J., “Development of a Space Suit Soft Upper Torso Mobility/Sizing Actuation

System with Focus on Prototype Development and Manned Testing” 2007-01-3169 ICES Conference, 2007. 2Graziosi, D., Splawn, W., Ferl, J., “Development of a Space Suit Soft Upper Torso Mobility/Sizing Actuation System”

2004-01-2342 ICES Conference, 2004. 3Graziosi, D., Splawn, W., Ferl, J., “Evaluation of a Rear Entry System for an Advanced Spacesuit” 2005-01-2976 ICES

Conference, 2005.

Figure 14. HyUT hatch release reach.

Figure 15. HyUT overhead reach.