Weaving the Future of Space Suits

• NASA researchers are testing 3D-reinforced fabrics to improve the impact resistance of the Hard Upper Torso (HUT) in space suits.
• Simulations show 3D woven materials outperform traditional 2D laminates by absorbing 73% of impact energy with significantly less structural damage.
• Future development aims to prevent catastrophic failures caused by delamination in current space suit designs.

The Problem with Current Space Suits

• Modern space suits rely on Composite HUTs (CHUT) made from 2D layers of S-2 glass fibers bound with epoxy resin.
• While these materials are stiff, they suffer from "delamination" where internal layers peel apart under impact, potentially causing leaks.
• Astronauts face constant risks from sharp rocks, geology tools, or equipment failures, as seen in the fictional scenario of 'The Martian'.

Research and Simulation

• Researchers from Materials Research & Design, Fiber Materials, Inc, and NASA’s Johnson Space Center evaluated weaving and braiding techniques to create 3D composites.
• Materials were infused with SC-15 epoxy using Resin Transfer Molding.
• In a simulated 280 Joule impact test:
  • 3D woven material absorbed 73% of energy (2.72 sq in damage).
  • Traditional 2D laminate absorbed 67% of energy (3.70 sq in damage).
  • Braided material absorbed 61% of energy (3.52 sq in damage).

Implications and Next Steps

• Although 3D composites have slightly lower initial shear strength, they deform under pressure without failing catastrophically.
• The team is pursuing an SBIR Phase II proposal to advance from simulation to physical prototype testing.