- 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.
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