Morphing: A Novel Approach to Astronaut Suit Sizing

The fitting of a spacesuit to an astronaut is an iterative process consisting of two parts. The first uses anthropometric data to provide an approximation of the suit components that will fit the astronaut. The second part is the subjective fitting, where small adjustments are made based on the astronaut s preference. By providing a better approximation of the correct suit components, the entire fit process time can be reduced significantly. The goals of this project are twofold: (1) To evaluate the effectiveness of the existing sizing algorithm for the Mark III Hybrid suit and (2) to determine what additional components are needed in order to provide adequate sizing for the existing astronaut population. A single subject was scanned using a 3D whole-body scanner (VITUS 3D) in the Mark III suit in eight different poses and four subjects in minimal clothing were also scanned in similar poses. The 3D external body scans of the suit and the subject are overlaid and visually aligned in a customized MATLAB program. The suit components were contracted or expanded linearly along the subjects limbs to match the subjects segmental lengths. Two independent measures were obtained from the morphing program on four subjects and compared with the existing sizing information. Two of the four subjects were in correspondence with the sizing algorithm and morphing results. The morphing outcome for a third subject, incompatible with the suit, suggested that an additional arm element at least 6 inches smaller than the existing smallest suit component would need to be acquired. The morphing result of the fourth subject, deemed incompatible with the suit using the sizing algorithm, indicated a different suit configuration which would be compatible. This configuration matched with the existing suit fit check data.