Advanced Material Options for the Portable Life Support System

Meeting an aggressive mass requirement is a challenge for new space suit development efforts, including that of the Exploration Extravehicular Mobility Unit Portable Life Support System (PLSS) government reference design. To reduce overall system mass, titanium was selected as the primary metal for the PLSS backplate and thermal loop. However, galvanically compatible metals (Hastelloy, Inconel, Monel) have relatively high densities and require further design complexities such as coatings and more challenging manufacturing. Efforts to reduce the mass of the government reference design for an International Space Station (ISS) or lunar mission were halted due to the government’s transition to a commercial Extravehicular Activity (EVA) services approach, but research was conducted into methodologies for mass savings using advanced materials. With the advent of a lunar Artemis mission and potential for future Mars missions, mass becomes a more critical driver going forward. Therefore, alternative materials and processes must be considered to fully close the mass requirement. There are many new materials and processes that can be considered; however, considerations must be made to ensure galvanic compatibility, radiation concerns for sensitive electronics, vacuum compatibility, tight tolerances, fluid compatibility with oxygen and water, and thread insert options. Individual PLSS components may have different requirements and need to be considered separately for reducing overall mass. This report will touch on comparisons between advanced materials, focusing on composites, additive manufacturing, and plastics. It will also address the different processes that may need to be applied when using these materials in the harsh environment of space. Lastly, it will look at specific components and make recommendations for options to reduce the mass of each one.