NASA’s space suit fitting process relies on precise body measurements and advanced sizing systems. They do this to keep astronauts safe and make sure missions run smoothly.
The agency collects anthropometric data and follows specialized protocols to match crew members with the right pressure garment systems. It’s a lot more complicated than just picking a size off the rack.
Space suit fitting always starts with detailed body measurements. Technicians break out the measuring tools and compare every number against suit component dimensions.
They measure everything—torso length, arm span, chest circumference, and a bunch of other body points. This creates a full sizing profile for each astronaut.
NASA considers how the human body changes in space. For example, astronauts’ spines stretch in microgravity, so backs get a little longer. Fitting specialists actually undersize torso sections a bit to account for this.
At Johnson Space Center in Houston, NASA keeps an inventory of suit parts in various sizes. Technicians mix and match arms, legs, torsos, and helmets to build a suit that fits each astronaut just right.
This modular approach means they can fit all sorts of body types without having to make a whole new suit every time. It’s pretty clever, honestly.
Before any mission, NASA tests each suit configuration through multiple fit checks. Astronauts wear their assigned suits during training to spot any pressure points, mobility restrictions, or comfort issues.
If they find a problem, they tweak the fit until it’s right.
If a suit doesn’t fit, it can create real safety risks during spacewalks or emergencies. When suits are too big, astronauts move around too much inside, which makes it tough to do delicate work outside the spacecraft.
Oversized gloves are a nightmare for gripping tools or operating controls. A loose helmet can block vision or mess with communications—definitely not ideal during a critical operation.
On the flip side, a suit that’s too tight causes pressure points, restricts blood flow, and limits how much astronauts can move. Tight spots can even make it hard to breathe or create hot spots that turn into injuries.
NASA sets strict fitting standards so suits maintain pressure and still allow astronauts to move freely. They test every configuration in pressure chambers and underwater training facilities to make sure it’s safe before anyone ever heads to space.
NASA’s sizing approach has changed a lot over the decades. In the early Mercury and Gemini programs, they made custom suits for each astronaut, but that got expensive and took too much time as crews grew.
The Apollo program introduced semi-modular designs with interchangeable parts. This helped cut costs and still kept the fit decent for different astronauts.
Modern Extravehicular Mobility Unit suits use computer modeling and 3D scanning to predict fit before anyone assembles a suit. It’s a big leap from the old days.
As commercial companies like SpaceX develop their own pressure suits—often designed for spacecraft operations rather than spacewalks—NASA continues to refine its approach. These new ideas are shaping how NASA thinks about sizing for future lunar and Mars missions.
NASA uses laser scanning and some pretty advanced algorithms to create custom-fitted spacesuits for astronauts. They combine exact measurements with modular parts that technicians can adjust for top performance during spacewalks.
The Advanced Suit Team at Johnson Space Center uses laser scanners to capture body measurements. This digital method blows old-school tape measures out of the water.
The scanner builds a detailed 3D map of each astronaut’s body. Engineers feed these numbers into algorithms that figure out the exact sizes for every suit component.
Key measurement areas include:
NASA fits a wildly diverse group—from the 1st to the 99th percentile, male and female. That’s a big challenge for spacesuit design and sizing.
The measurement data goes straight into NASA’s fitting database. Engineers use it to pick the right EMU parts before astronauts ever try anything on.
NASA’s EMU spacesuits use a modular design. They don’t make a custom suit for every astronaut, and that’s on purpose.
Each suit consists of multiple interchangeable pieces. Technicians can size each part independently to get an optimal fit. Arms, legs, torsos, and helmets all come in a range of sizes.
Modular components include:
Adjusting one part, like arm length, can throw off the fit somewhere else—say, the chest or legs. Engineers often run through several iterations to get everything lined up.
This modular system lets NASA keep fewer total components on hand and still fit a broad range of astronauts. It’s way more efficient than making a custom suit for everyone.
NASA runs specialized fitting facilities at Johnson Space Center. Here, astronauts can try on suits and test the fit in all sorts of conditions before heading out for real spacewalks.
The Neutral Buoyancy Laboratory is the main training spot. It’s a massive pool with a full-scale space station replica on the bottom. Astronauts practice spacewalks underwater in full EMU suits.
Vacuum chambers offer another way to test. Astronauts wear flight-ready suits in these chambers to see how the hardware holds up under space-like conditions.
NASA also runs on-orbit fit checks on the International Space Station. Crew members suit up, pressurize their suits, and give feedback to the ground about fit and comfort.
During these checks, astronauts follow detailed lists while ground controllers look out for any issues. Engineers put together troubleshooting guides for problems like spinal growth in microgravity.
The whole fitting process is a team effort. Astronauts and engineers talk constantly to spot and fix problems before any critical mission.
Three main components really decide how well a modern spacesuit fits and works. The hard upper torso provides structure, the lower torso gives mobility and comfort, and helmet-glove integration finishes the life support system.
The hard upper torso is the backbone of NASA’s EMU system. This rigid fiberglass shell holds all the life support gear and keeps pressure inside.
Primary dimensions are chest circumference, shoulder width, and arm length. NASA keeps multiple torso sizes to fit crew members from the 5th to 95th percentile. Arm assemblies connect through rotating shoulder joints.
Technicians adjust internal padding to match each astronaut’s body and comfort preferences. They tweak foam thickness to prevent pressure points during long spacewalks.
Connection interfaces attach the torso to helmet rings and lower body assemblies. These joints must stay sealed under pressure but still let astronauts move freely. The torso also holds mounting points for portable life support gear.
Manufacturing differences mean even identical torso sizes can fit a little differently. That’s why each assignment gets its own fitting session.
The lower torso assembly covers waist sizing, leg dimensions, and boot integration for full mobility. Soft fabric parts flex with body movement and still keep the suit pressurized.
Waist adjustments rely on straps and elastic panels to fit different people. The waist ring connects to the hard upper torso with a sealed bearing, letting astronauts rotate while keeping life support running.
Leg sizing includes thigh circumference, inseam, and ankle measurements. NASA keeps several leg lengths on hand for the best fit. Restraint layers in the fabric stop ballooning when the suit is pressurized.
Boot systems attach directly to the legs. Each boot has its own pressure seals and ankle joints. Sizing is based on standard shoe measurements but also accounts for suit thickness.
Thermal layers in the lower torso keep astronauts’ temperatures in check. These garments contain cooling water tubes and insulation. A good fit spreads heat evenly across the body.
Helmet and glove systems complete the pressure seal and let astronauts see and work in space. These parts need to seal perfectly with the main suit.
Helmet sizing looks at head circumference and vertical clearance. The clear bubble gives wide vision and holds communication gear. Padding inside the helmet keeps the head in the right spot for a good view.
Gloves are probably the hardest part to fit. Each glove needs palm width, finger length, and wrist measurements. NASA actually makes custom gloves for every astronaut for better dexterity.
Pressure seals between components use metal rings and rubber gaskets. These must stay leak-proof no matter what. Quick changes between missions are possible thanks to this system.
Integration testing is a must. Astronauts run through mobility tests in full suits to find and fix any fit issues before a space mission.
The United States uses three main types of spacesuits, each built for a different job. The Extravehicular Mobility Unit is the go-to for spacewalks, while training suits help astronauts get ready, and crew survival suits keep them safe during launch and reentry.
The EMU has been the workhorse for American spacewalks since the 1980s. It’s basically a personal spacecraft that lets astronauts work outside the International Space Station.
The EMU combines several key parts. The hard upper torso holds life support systems. Arms and gloves give the dexterity needed for tough tasks. The helmet keeps everything pressurized with a strong plastic shell.
The suit weighs about 280 pounds on Earth, but in space, that’s not an issue. NASA’s current EMUs are getting old, so Axiom Space is building next-gen replacements with better mobility and new tech.
NASA makes a clear distinction between training suits and the ones astronauts actually wear in space. Training suits let astronauts practice movements and procedures without full operational systems.
Training suits are built tough for repeated use and use simpler life support gear. The Neutral Buoyancy Lab uses special training EMUs for underwater practice.
Training Suit Characteristics:
Operational suits, on the other hand, go through tons of tests and quality checks. Each flight suit gets custom fitting and safety certification. NASA always keeps backup units ready for every spacewalk.
Back in Apollo days, International Latex Corporation made custom-fitted suits for each astronaut. Every moonwalker got a suit tailored to them, and a single mission needed up to 15 suits to support all the exploration activities.
Crew survival suits keep astronauts safe during the intense launch and reentry stages. These suits aren’t like the big, clunky EMU systems built for spacewalks.
SpaceX Dragon and Boeing Starliner crews use the Advanced Crew Escape Suit on commercial missions. These suits hook right up to the spacecraft’s environmental systems.
The bright orange color? It’s all about making astronauts easy to spot if there’s an emergency and rescuers need to find them fast.
Survival Suit Functions:
Modern crew suits look a lot sleeker than the old, heavy-duty spacewalk ones. SpaceX’s pressure suit, for example, comes with gloves that work on touchscreens and built-in cooling.
These suits really focus on keeping the crew alive during the riskiest parts of the flight, not for long stints outside.
Russian Sokol suits also keep American astronauts safe when they ride in Soyuz spacecraft. NASA’s international partnerships mean they have to juggle a bunch of spacesuit standards.
NASA engineers wrestle with some pretty wild problems when they build spacesuits that keep astronauts safe. They need to fit a huge range of body types, but they can’t make a hundred different sizes.
NASA’s team has to design suits for astronauts from the tiniest to the tallest and broadest. That’s way more complicated than sizing up a pair of jeans.
Astronauts come in all shapes—maybe big shoulders, skinny arms, long legs, short torsos. There’s no such thing as an “average” astronaut.
On the International Space Station, astronauts use the Extravehicular Mobility Units in just three main torso sizes: medium, large, and extra-large. Female astronauts often end up with the medium Hard Upper Torso, the smallest size they’ve got.
Suit fitting kicks off with lots of body measurements. Engineers crunch the numbers to suggest which suit pieces will work best.
But preferences matter too—some astronauts like a tighter fit, others want a bit more room.
Body composition changes the game even when the tape measure says two astronauts are the same size. Muscle mass and body shape can mean one person needs a totally different setup than another.
Back in the early NASA days, they built a custom suit for every single astronaut. That stopped making sense once the shuttle and ISS programs brought in way more people.
NASA switched over to modular suits. Now, they mix and match suit parts to fit different folks.
This approach saves money and storage space, but it’s not perfect. It brings its own set of sizing headaches.
Right now, the ISS has four suits ready for spacewalks: two with large torsos, one medium, and one extra-large. Three more spares sit unconfigured.
Swapping out suit pieces takes ages. Changing a Hard Upper Torso can eat up about 12 hours. That makes it tough to quickly reconfigure suits for new arrivals.
Manufacturing isn’t always perfectly consistent, either. Two suit parts marked the same size might fit differently because of small differences from the factory.
NASA made headlines when they had to shuffle spacewalk assignments due to suit fit problems. The first all-female spacewalk got canceled, which really put the spotlight on these challenges.
Astronauts’ suit size preferences can change in microgravity. They might train in one size on Earth, but once they’re floating, the suit feels totally different.
NASA Administrator Jim Bridenstine said they’d do better at fitting everyone for future missions. The agency’s working on new suits for lunar missions that need different features than the current ISS suits.
For Mars, engineers might go back to making custom-fitted suits. They compare it to having work clothes tailored just for you—something you can trust for long days on the job.
Suit maintenance eats up a lot of time. Astronauts spend hours checking and caring for suits, which means less time for science. New designs aim to make maintenance easier and fitting more flexible.
Getting ready for a spacewalk isn’t just “suit up and go.” Astronauts and ground teams go through a whole process of pre-mission checks, last-minute tweaks, and backup plans in case something goes wrong outside the ISS.
NASA runs detailed fit verification drills before spacewalks using the EMU suit. Crew members get suited up, pressurize, and ground teams watch every step.
Astronauts go through checklists and give feedback about comfort and how well they can move. They test arm swings, joint bends, and helmet visibility.
Each person runs through specific moves to make sure the suit lets them reach and twist as needed.
Key fit checks:
The ISS usually keeps just two EMU suits ready for spacewalks—one for medium builds, one for large. That limits who can go outside for certain missions.
Ground teams track fit check results and compare them to earlier data. They look for any body changes or suit performance shifts.
A few hours before a spacewalk, technicians tweak EMU parts for each astronaut. They adjust helmet positions, cooling connections, and make sure life support systems match the person wearing the suit.
The hard upper torso needs to match shoulder width exactly. If it’s off, arm movement suffers and the astronaut could get uncomfortable fast.
Techs use special tools to adjust padding and supports inside the suit.
Leg and waist adjustments matter too. The metal seal between the top and bottom of the suit has to be just right or the suit won’t hold pressure.
Common last-minute tweaks:
Glove fit gets extra attention. Astronauts need precise finger control for repairs, and bad gloves mean hand fatigue or slower work.
Sometimes, astronauts run into fit problems mid-spacewalk. Mission control jumps in with advice if someone’s uncomfortable, can’t move well, or if something breaks.
Minor stuff, like shifting helmet padding or tweaking the cooling, can be fixed on the fly. Astronauts handle these without heading back to the airlock.
If it’s a bigger issue—like serious discomfort or stuck joints—protocol says get back inside, no questions asked.
Emergency rules cover what happens if a suit part fails or shifts during EVA. Backup astronauts stay ready to help with rescues if needed.
Spacewalks always happen in pairs. Having a partner means there’s always someone to help spot or fix fit problems that pop up.
The ISS only has a handful of Extravehicular Mobility Units, each with set size options. NASA keeps a close eye on suit storage and maintenance so astronauts always have something that fits for spacewalks or emergencies.
The space station keeps a specific number of EMU suits ready for the crew. These suits double as backup in emergencies and as the main gear for planned spacewalks.
NASA usually has two to four full EMU systems on the ISS at a time. Each suit has over 18,000 parts and takes up about as much space as a small fridge when it’s all put together.
These suits have to fit the whole range of body types among international crew members. That’s a headache since astronauts come from all over the world and in all shapes and sizes.
Ground teams work with flight engineers to match suits to each mission’s crew. KBR engineers help by tracking suit parts and keeping records for the best fit.
EMU pieces get stored separately to save space and make it easier to build the right suit for each astronaut. The modular system lets ground teams pick the best sizes for every person.
Hard Upper Torso parts come in different sizes and are the main piece for fit. Arms, gloves, helmets, and lower parts snap on to make the full suit.
Astronauts get laser-scanned on Earth for exact measurements. KBR engineers run these numbers through special algorithms to predict what suit parts each person needs.
Suit parts get stashed in different places on the ISS:
This setup lets astronauts get suited up quickly, whether it’s for a scheduled EVA or an emergency.
Flight engineers check EMUs regularly to keep them working right. They run pressure tests, inspect parts, and do minor repairs with special tools.
On-orbit fit checks happen before every spacewalk. Crew members suit up, pressurize, and give feedback to ground control about comfort and movement.
Ground teams use troubleshooting guides at Mission Control to fix surprise fit problems. Astronauts’ spines can stretch in microgravity, so sometimes they need size tweaks no one expected.
Collins Aerospace and other contractors offer remote help during spacewalks. Engineers watch suit data and suggest adjustments if astronauts report fit issues.
Maintenance includes swapping batteries, checking cooling systems, and testing comms gear. These steps keep every EMU ready for long ISS missions.
Spacesuit designers now focus on using advanced materials and digital tools to make suits fit perfectly. These upgrades address the old problems with mobility and comfort that came with “one-size-fits-most” suits.
Active compression tech is a big leap from the classic bulky suits. Instead of surrounding astronauts with pressurized air, these new suits use mechanical counter-pressure right on the skin.
The biomimetic design copies how our skin naturally handles pressure. Smart fabrics have sensors that track temperature, movement, and pressure changes as they happen.
Sensors can dial up or ease off compression in different areas. Joints and shoulders, for example, get extra flexibility when the suit senses movement.
| Traditional Suits | Active Compression |
|---|---|
| Gas-filled chambers | Direct skin pressure |
| Limited joint mobility | Enhanced flexibility |
| Fixed pressure levels | Adaptive compression |
NASA’s studies show these suits cut down on astronaut fatigue during long spacewalks. They get rid of that ballooned-up feeling that made old suits so hard to move in.
Shape-memory alloys bend and return to shape when you change the temperature or run a current through them. Suit designers put these materials in joints, seals, and adjustable parts.
The alloys “remember” their shape and snap back when activated. That means self-adjusting suit pieces that move with the astronaut.
In gloves, temperature-activated alloys can boost grip strength in the cold. Astronauts can also hit a control to trigger size adjustments using electrical signals.
These alloys help make adaptive seals too. Helmet and suit joints can tighten or loosen on their own, depending on what’s needed.
This tech means astronauts spend less time fiddling with their suits and more time actually working. It also lowers the risk of a bad fit during crucial moments.
Full-body scanning tech now builds detailed 3D models of each astronaut’s body. Professor Bonnie Dunbar at Texas A&M University is leading the charge on these custom-fit methods, thanks to NASA grants.
Advanced scanning systems pick up thousands of measurement points all over the body. They gather info on muscle mass, joint movement, and posture quirks.
Computer algorithms then turn that scan data into specs for making individual spacesuits. Dunbar calls each suit “a spacecraft molded around your body,” which sounds about right.
The scanning itself wraps up in under 30 minutes. Teams run multiple scans to catch changes from breathing and natural shifts in body position.
NASA wants to roll out this tech for lunar missions and, eventually, Mars. Custom fits should finally fix the annoying mix-and-match sizing that used to make spacesuits awkward.
Digital manufacturing speeds things up, too. The new suits come together in weeks instead of months, which definitely helps with training and mission prep.
American companies and research centers push spacesuit innovation forward by teaming up with NASA and running their own projects. They blend decades of aerospace know-how with new manufacturing to create next-generation pressure garments for government and commercial astronauts alike.
Axiom Space heads up lunar surface suit development through a $228 million NASA contract. The Houston-based team builds modular suits with a rear-entry hatch—kind of like stepping into a washing machine.
Their engineers have really put these prototypes through their paces. NASA astronaut Victor Glover even joined Axiom’s sandbox tests for lunar sample collection.
Collins Aerospace landed the main spacewalk suit contract, worth $97.2 million. They’re building on decades of experience from the Space Shuttle era.
Collins still maintains the EMU (Extravehicular Mobility Unit) suits used on the ISS. Now, those 43-year-old suits are getting swapped out for modern hybrid torsos that mix rigid protection with flexible materials.
SpaceX is developing commercial EVA suits on their own dime. Their design adapts the crew capsule suit for spacewalks, using spiral zippers and umbilical life support connections.
The Polaris Dawn mission will be the first to test SpaceX’s commercial spacewalk suits. These new suits ditch the bulky life support backpacks and focus on keeping things mobile.
NASA’s Johnson Space Center is home to the main spacesuit engineering teams. The Space Suit and Crew Survival Systems Branch runs all American pressure garment programs.
Johnson’s engineers manage the U.S. Spacesuit Knowledge Capture Program, which saves decades of design wisdom as senior engineers retire.
The center offers testing facilities for new suits. Companies like Axiom and Collins run prototype trials in Johnson’s unique chambers and pools.
NASA switched from owning suits to renting them from contractors. That gives companies more design freedom and saves NASA money for Artemis.
Johnson teams also support commercial crew programs. They check private suits to make sure they meet or beat NASA’s safety standards.
The Human Spaceflight Laboratory at the University of North Dakota is pioneering 3D-printed spacesuit parts. Their team makes flexible elbows and ankle boots with additive manufacturing.
HSFL researchers mix flexible filaments with mesh fabrics to boost durability. This could cut costs for commercial space tourism companies.
University labs work on advanced sizing methods for a wider range of body types. Traditional EMU suits limit who can do spacewalks because of rigid torso sizes.
Academic teams study pressure garment biomechanics to reduce astronaut fatigue. Better fits mean less effort for basic movements during long EVAs.
These schools are also training the next generation of spacesuit engineers. A lot of their grads end up at NASA, Axiom, Collins, and other aerospace firms building the future of pressure garments.
Movie studios and schools use specially designed spacesuit replicas that need a different approach than NASA’s real gear. These suits focus on looking right and teaching, not life support.
Hollywood and indie filmmakers turn to prop houses for screen-accurate spacesuit replicas. Companies like Aerospace Costume Company and Replica Space Suits base their designs on NASA suits, but tweak them for filming.
Replica suits usually use lightweight materials instead of NASA’s 20-plus layers. Costume crews modify chest plates, helmet latches, and joints to fit cameras and lights.
Fitting film spacesuits means thinking about:
Rental shops stock sizes from small to extra-large. They even have multiple helmet styles, from Mercury capsule helmets to today’s EVA gear.
Actors go through custom fittings to learn a suit’s limits. Directors sometimes realize that real spacesuit movement is slower and clunkier than what looks dramatic on screen.
Science museums and educational groups use simplified suits for hands-on learning. The Smithsonian National Air and Space Museum even lets visitors try on spacesuits to feel their weight and bulk.
NASA’s education team sends schools spacesuit demo kits. These include partial suits for students to check out and wear during STEM activities.
Educational fitting means:
Space camps use working spacesuit trainers. These let kids learn how to put on a suit and experience the movement restrictions astronauts deal with.
Museum educators highlight the engineering behind real suits. They show how companies like ILC Dover made flexible joints and pressure seals to keep astronauts safe.
Film and educational suits skip key safety features to save on cost and complexity. Real NASA suits go through pressure chambers, dust tests, and wild temperature swings.
Here’s how they compare:
| Operational Suits | Replica Suits |
|---|---|
| 20+ protective layers | 2-3 cosmetic layers |
| $75,000-$100,000 cost | $5,000-$15,000 cost |
| Life support integration | No functional systems |
| Rigorous safety testing | Basic durability testing |
Replicas leave out the life support, cooling, and comms gear. They just need to look right, not protect anyone from space.
Educational models sometimes use clear materials so students can see inside. It’s a neat way to show how real suit joints work while holding pressure.
Film suits often change proportions to look better on camera. Actual NASA suits are bulkier because they pack in life support and protection layers—things actors don’t need when filming.
NASA and private companies are working on new ways to fit spacesuits, aiming to finally solve old problems with astronaut safety and comfort. The focus is on fitting more body types for future missions and customizing for each space environment.
NASA’s Artemis program needs suits that work for both men and women on the Moon by 2026. The agency picked Axiom Space for $228 million to build modular surface suits with swappable parts.
ISS suits are now 43 years old and overdue for retirement. Collins Aerospace got $97.2 million to design new EVAs that fix old mobility issues. The new suits will let astronauts reach chest displays without awkward arm moves.
What’s needed for upcoming missions:
The 2019 spacewalk delay made the fitting problem obvious. Christina Koch and Anne McClain both needed medium torsos, but only one was ready. NASA now demands more flexible sizing in contracts.
Old-school spacesuits were mostly built for male military types. Now, designers are finally paying attention to differences in male and female body shapes.
Axiom Space uses a “bespoke suit” method. Technicians measure each astronaut in detail, then pick arms, legs, gloves, and boots from a big inventory for a custom fit.
Axiom’s rear-entry design ditches the rigid frame that can hurt during donning. Female astronauts benefit from the softer outer pressure garment, which adapts better to different shapes.
Collins Aerospace created an adjustable hybrid torso that fits a broader range of chest and shoulder sizes. This finally addresses the fitting issues that made spacewalks harder for women.
Lunar surface missions need suits that move differently than orbital ones. Astronauts have to squat, kneel, and collect samples while staying fully pressurized.
Axiom put their lunar prototypes through sandbox tests with astronaut Victor Glover at NASA Johnson. These suits use special joints at the shoulders, elbows, hips, and knees for surface work.
Planetary suit features:
SpaceX is going for fully custom-fitted suits for each crew member. Their Polaris Dawn mission will be the first to show off EVA suits tailored to individuals, not just modular parts.
3D scanning now measures astronauts precisely. In the future, 3D printing might let teams make suit parts shaped for each person and mission.
Space suit fitting is a complicated, highly customized process that varies between NASA missions and commercial space travel. Astronauts use modular sizing systems, while future tourists might get different fitting experiences depending on their provider.
Modern NASA astronauts use a modular system instead of fully custom suits. The agency switched to mix-and-match parts when astronaut classes got bigger during the Shuttle era.
Suits come in three main torso sizes: medium, large, and extra-large Hard Upper Torsos. Astronauts then combine those with different arms, legs, and gloves for the best fit.
Suit fitting takes several tries and tweaks. Engineers know everyone’s body is different—someone might need large arms but a medium torso, and one change can affect the rest.
Fitting a space suit is almost an art, according to NASA engineers. Test subjects have their own preferences for how a suit should feel. Multiple fit-checks help dial in the best setup.
NASA uses several layers of materials for its Extravehicular Mobility Units. The outer layer shields astronauts from micrometeoroids and helps with thermal protection in space.
Inside the suit, pressure bladders keep a breathable atmosphere using tough, specialized fabrics. These materials have to handle about 3 pounds of pressure per square inch, yet they still need to stay flexible enough so astronauts can move.
Engineers pick fabrics that resist tears, punctures, and wild temperature swings. Materials need to work in temperatures anywhere from minus 250 to plus 250 degrees Fahrenheit—which is pretty wild if you think about it.
Modern suits also come with cooling garments that have water-filled tubes running through them. These help wick away sweat and keep astronauts’ temperatures in check during a spacewalk.
NASA’s engineers are now building new suits for lunar missions, and they’re really focusing on mobility in the legs. The suits they use on the International Space Station mainly help with upper body movement, since astronauts spend a lot of time working along handrails.
Future designs aim to cut down on maintenance time and how long it takes astronauts to get ready. Right now, astronauts spend a lot of time keeping the suits in top shape—probably more than anyone would like.
Commercial space companies are trying out different ways to fit and design suits. Some might even go back to more custom fits, especially since astronauts on long missions need to wear the suits again and again.
The new goal? Make suits feel more like trusty work clothes. Engineers want them to be as comfortable and reliable as a good pair of coveralls—something astronauts can just put on and get to work.
One NASA space suit costs about $500 million, factoring in development, testing, and all the manufacturing. That price tag comes from the insane amount of engineering and safety testing needed for a suit that can handle spacewalks.
A lot of that cost comes from the suit’s life support systems and the need for endless rounds of testing. Each suit has to protect against radiation, extreme temperatures, and the vacuum of space—no shortcuts allowed.
Commercial space tourism companies are working on cheaper suits for their own missions. Their suits can cost a lot less because they don’t need all the features of a full EVA suit.
Making these suits is still pricey, though, since they don’t make many and every part has to pass strict quality checks. Every component gets tested a bunch of times before it ever makes it into a real suit.
A full NASA Extravehicular Mobility Unit tips the scale at about 280 pounds, including the suit, backpack, helmet, and all the gear needed for a spacewalk.
Engineers try to spread out the weight so astronauts can move and stay comfortable, even after wearing the suit for hours.
Suits for commercial space tourism are a lot lighter because they’re made for different types of missions. Crew survival suits aren’t pressurized, so they’re more flexible and weigh less than EVA suits.
Weight matters even more for lunar missions, since astronauts have to walk and work on the surface. Designers have to find a balance between keeping astronauts safe and letting them move around.
Commercial space companies build suits for specific mission profiles, not for general spacewalks. SpaceX, Blue Origin, and Virgin Galactic all take their own approach, since their spacecraft have different needs.
Most commercial space tourism suits work as crew survival gear. They protect passengers during launch, flight, and landing, whether the mission goes suborbital or orbital.
These suits focus way more on comfort and simplicity than on heavy-duty life support. Tourists just stay inside a pressurized cabin—nobody expects them to head outside for a spacewalk.
When it comes to fitting, commercial suits usually go for quick sizing and easy prep. Companies want to make sure passengers can get ready fast, with hardly any training.
