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ICES-2020-449

U.S. Spacesuit Knowledge Capture – Documenting the Anatomy of a Spacesuit

Cinda Chullen1 NASA Johnson Space Center, Houston, Texas, 77058

and

Vladenka R. Oliva2 Jacobs, Houston, Texas, 77058

After more than 45 years since the United States last landed humans on the Moon, Space Policy Directive 1 now directs NASA to return astronauts to the Moon by 2024, followed by missions to Mars and beyond. To assist in the success of these future missions, the U.S. Spacesuit Knowledge Capture (SKC) Program can offer current and legacy spacesuit-related knowledge to scientists, engineers, and technicians. Collecting and sharing spacesuit-related knowledge has been the program’s primary function since its 2007 inception, and it continues to adopt novel ways to contribute knowledge to the spacesuit community. In the fall of 2019, the SKC Program accepted the responsibility to coordinate the electronic recording of the future spacesuits’ buildup. This new, next-generation spacesuit is also known as the Exploration Extravehicular Mobility Unit. The electronic documentation will include special- event videography services, high-speed video production, photography, editing, and full production of several small vignettes. These archives will provide a pattern for additional next-generation spacesuits to be built. It will be added to the SKC Program’s expansive archived collection of spacesuit-related knowledge. This archived collection of knowledge represents over 5 decades of spacesuit legacy from the Apollo era to the pursuit of Mars and beyond. This legacy knowledge consists of lessons and events on spacesuits and ancillary material that contain technical knowledge and experiential learning that encourages the audience to retain and use this information. Some of this knowledge is essential for successful spaceflight missions. For more than a decade, the SKC Program has captured this valuable knowledge through sponsoring and recording 119 events. The NASA Engineering and Safety Center (NESC) and the Extravehicular Activity Office have sustained and supported the SKC Program. The NESC Academy continues to maintain the SKC Program’s electronic library, which is accessible to viewers. Sharing these lessons and events gives NASA, space partners, academia, and others an opportunity to expand their knowledge pertaining to the spacesuit. This paper depicts NASA’s new spacesuits, reveals the SKC Program’s 2019 accomplishments and statistics, shares the value of legacy and current spacesuit knowledge, provides insight into the SKC Program’s historical and future emphases, and introduces a plan to document the anatomy of the next-generation spacesuits. It provides information about the SKC Program’s catalog and includes links that lead the reader to the program’s collection of archived knowledge. As the program continues to evolve, its ambition is to tell the story about one of our nation’s greatest technical gems – the NASA spacesuit.

Nomenclature CTSD = Crew and Thermal Systems Division DAA = Document Availability Authorization

1 U.S. Spacesuit Knowledge Capture Program Manager and Project Engineer, Space Suit and Crew Survival Systems Branch, Crew and Thermal Systems Division, NASA Parkway, Houston, TX 77058/EC5. 2 U.S. Spacesuit Knowledge Capture Program Administrator and Technical Editor, Science and Exploration Department, 2224 Bay Area Blvd., Houston, TX 77058/JE6WA. DVT = development verification test EC5 = Space Suit and Crew Survival Systems Branch EMU = Extravehicular Mobility Unit EVA = extravehicular activity ISS = International Space Station JSC = Johnson Space Center NEN = NASA Engineering Network NESC = NASA Engineering and Safety Center OCSS = Orion Crew Survival System PLSS = Portable Life Support System SKC = U.S. Spacesuit Knowledge Capture SLS = Space Launch System SME = subject-matter expert xEMU = Exploration Extravehicular Mobility Unit

I. Introduction S the 2024 target date approaches for NASA to return humans to the Moon, the NASA Johnson Space Center A(JSC) continues its mission to lead human space exploration. Lessons and knowledge acquired from past Moon landings along with documentation of more recently attained knowledge are essential for a return. However, past knowledge, although once common and previously applied, is not necessarily known and readily available now. To build on past knowledge, lost, archived, and forgotten lessons need to be rediscovered and applied. Equally important is the new knowledge that will be generated as we endeavor to return to the Moon. The U.S. Spacesuit Knowledge Capture (SKC) Program (Figure 1) contributes by recognizing useful spacesuit-related knowledge and by documenting, retrieving, preserving, and sharing that knowledge with the NASA community. Users of the SKC Program’s documented lessons are beneficiaries of knowledge that can be used as essential building blocks to send humans farther into space than ever before. The SKC Program, created in 2007, has recorded 119 spacesuit- related events that are accessible to the NASA community. The public can access 87 of these recordings. This collection includes courses, interviews, workshops, and vignettes that focus on historical and current spacesuit information and peripheral topics. Most of these recordings are approximately 1 hour long and are packed with nuggets of useful information that represent over 5 decades of spacesuit Figure 1. U.S. Spacesuit Knowledge history. Yet, the SKC Program is more than a history lesson; it is a Capture logo (image by Gordon valuable tool that can help engineers, scientists, and technicians build Andrews and Jeannie Corte). the next-generation spacesuits, which this paper reveals.

II. Background Space Policy Directive 1 tasked NASA to return to the Moon, with later missions to Mars and beyond.1 To return to the Moon, NASA has planned three missions: Artemis I, II, and III. Artemis I will launch uncrewed in 2021 and will be the first flight test of the Space Launch System (SLS) and Orion vehicle as an integrated system.2,3,4 Artemis II will launch the first crew to fly by the Moon aboard the SLS and Orion in late 2022 or early 2023.4,5 Artemis III will launch the first crew to the lunar surface in 2024.4-7 To meet Space Policy Directive 1 and the objectives of the Artemis Program, NASA is building the next-generation spacesuits. To help design the new spacesuits, NASA has implemented many lessons learned from Apollo, Space Shuttle, and the International Space Station (ISS), including lessons learned from failures.8 On October 15, 2019, NASA unveiled the two next-generation spacesuits that will be used for the Artemis Program astronauts and the ISS: the Orion Crew Survival System (OCSS) and Exploration Extravehicular Mobility Unit (xEMU).9 To design the OCSS and xEMU, NASA used knowledge gained from legacy spacesuits to upgrade and incorporate new technologies within the new spacesuits. Spacesuit technology was also added as a result of collaboration between NASA’s spacesuit engineers and outside entities who have dealt with vehicle safety and environmental challenges such as that of the lunar surface.9 2

International Conference on Environmental Systems A. The Orion Crew Survival System The OCSS (Figure 2) will be used to send humans to and from the Moon. In preparation for a lunar mission, astronauts will test the OCSS on Artemis II in late 2022 or early 2023.4 The OCSS is distinquishable from the xEMU; it does not have a Portable Life Support System (PLSS). The OCSS is tailored to the astronaut and will be worn inside the Orion vehicle during launch, entry, and reentry to protect astronauts from potential vehicle system failures and fires. This spacesuit will connect to the vehicle’s oxygen system for crew survival; if the vehicle becomes depressed, the OCSS will protect the crew from zero pressure outside the spacesuit.9 The OCSS is equipped with an integrated lifesaving device that will inflate upon splashdown to keep the crewmembers afloat if they are outside the vehicle. If a rescue is needed, lights and a satellite beacon are also being incorporated into this bright orange spacesuit for easier detection. It is also a dry suit that is designed to keep the astronaut dry and warm when in water.9

B. The Exploration Extravehicular Mobility Unit NASA has been working on an exploration suit for the last 15 years.10 This work has culminated into the new xEMU prototype (Figure 3). An xEMU demonstration spacesuit will be built and tested aboard the ISS, and a lunar suit will be prepared for the Artemis III mission in 2024. This suit is designed with dust-tolerant features and will incorporate more advanced technologies than the current Extravehicular Mobility Unit (EMU). The EMU design was used on the Space Shuttle and has been modified for use on the ISS, culminating in over 37 years of operation.11 The xEMU will allow crewmembers to perform autonomous extravehicular exploration, science, construction, maintenance, and contingency operations in extreme environments. To help NASA meet its Figure 2. OCSS prototype (image by spacesuit objectives for NASA). future missions, NASA is building a development verification test (DVT) unit of the xEMU incorporating all the desired technology and features to demonstrate its functionality. The DVT unit will be the first completely assembled unit. NASA plans to follow the DVT unit with qualification and flight units. The qualification unit will be tested rigorously on the ground before humans wear them on the lunar surface in 2024. At the end of the qualification unit, a crewmember will test the spacesuit in a vacuum chamber on the ground. After successful test of the spacesuit qualification unit, the flight units will be ready for tests aboard the ISS and delivery to the Gateway Program.9 The xEMU involves a common architecture platform that is broken into several configurations to address the combined set of project requirements. The goal is to minimize architectural differences between the different configurations and use a modular system to allow components to be added or augmented in the future, with minimal impact to support extravehicular activities (EVAs) at multiple destinations. This valuable feature will help meet currently known and unknown needs and increase the possibility of extending the suit’s lifespan and travel distance for future human space 9 exploration. If certain spacesuit components need to be replaced during a mission, astronauts will have the ability to use interchangeable parts instead Figure 3. xEMU prototype of requiring the suit to be repaired or maintained only on Earth. This (image by NASA). minimization objective supports the ISS demonstration and the lunar surface configurations.

International Conference on Environmental Systems The xEMU configuration for the ISS demonstration is a low Earth orbit microgravity design baseline. This configuration will have the same framework as the one for the lunar surface. One unit of this configuration is scheduled to be delivered to the ISS Program by the end of 2023.5 Figure 4 is a rendition of the current configuration design.12 The xEMU configuration for the lunar surface-system suit includes two units that are targeted to be delivered to the Gateway Program slightly ahead of the ISS demonstration unit. These units support the 2024 target date to return humans to the Moon.5 NASA is also planning for a sustained spacesuit architecture (Figure 5). This configuration supports deep-space operations and more long-term use with upgrades planned in certain areas of this Figure 4. xEMU current Figure 5. xEMU sustained (image spacesuit (e.g., arms, legs, configuration design by NASA). electronics, etc.).5 (image by NASA).

III. 2019 Accomplishments and Statistics For a program that the Space Suit and Crew Survival Systems Branch (EC5) initiated in 2007 as a grassroots effort without funding, the SKC Program has built momentum throughout the years. The program has become an increasingly sought-after tool to capture and share spacesuit-related knowledge. Beginning in 2010, the program received funding. Since then, its funding sources have varied. In 2018, EVA Office Manager Chris Hansen began funding the SKC Program and, in 2019, he helped broaden its range by requesting that it help orchestrate documenting the buildup for the new spacesuit. A historical perspective of the program’s evolution is documented in previously published ICES papers.13-21 The SKC Program continues to host knowledge capture events and currently has 119 recordings archived. Ninety- one events (total publicly available plus restricted access) have been approved through the NASA Document Availability Authorization (DAA) system. The DAA system is a mechanism used to determine export-controlled content. Using this system, NASA has approved 87 of these events as releasable to the public, and four events have restricted access and are accessible only to NASA employees and contractors. These 91 events are being archived on the NASA Engineering and Safety Center (NESC) Academy’s Web site and are accessible at this URL: https://nescacademy.nasa.gov/catalogs/cfd4cdc970c046358afc1c2e5f72a0554d. Four SKC Program events contain sensitive information and are archived behind a firewall. Only NASA employees and contractors can access the program’s sensitive events by request and approval. Twenty events are being edited and prepared before they are submitted into the DAA system. The remaining four events are being processed in the DAA system for approval. Table 1 breaks down these 119 events into the five categories. The “U.S. Spacesuit Knowledge Capture Series Catalog Revision C,” Crew and Thermal Systems Division (CTSD)–SS–3487, describes each SKC Program event that occurred since the program’s inception through mid-2020.22

International Conference on Environmental Systems Table 1. SKC Events Categories of Events Number of Events Publicly available 87* Preparing to submit into the DAA 20‡ Restricted access 4* Sensitive 4‡ In DAA process 4* Total number of events 119 *95 events have been submitted into DAA system ‡24 events have not been submitted into DAA system

In 2019, the SKC Program recorded one interview, two vignettes, and nine courses. During an interview, retired NESC Technical Fellow Hank Rotter, who worked with NASA for over 56 years, revealed his knowledge about his flight and hardware experience at NASA. The two vignettes included one from retired Apollo PLSS expert Maurice Carson, and one from retired Mercury spacesuit technician Allan Rochford. Both vignettes were packed with lessons that were shared through stories. The nine courses included a summer series of four shared by Joe McMann, retired NASA chemical engineer, with over 55 years of spacesuit-related experience (35 years as a NASA employee). Mr. McMann’s lessons included setting requirements and starting a project; a two-part lesson on how to use the tools of a recovery plan and how to investigate and identify the immediate, contributing, and root causes by presenting actual failures that JSC encountered; and assessing performance, dealing with committees, and handling people and hardware. Dr. Eugene Ungar, a NASA senior thermal and fluids analyst in CTSD with 30 years of experience, shared a series of three lessons that ranged from touch temperature limits to leakage correlation from helium to working fluid. Amy Ross, a 25-year NASA veteran who specializes in pressure garments, discussed how the Advanced Suit Lab tests the pressure garment designs. The program’s year ended with Mark Craig, former associate director of JSC, who has 48 years of service in the space program. During his course, he discussed the evolution of NASA human spaceflight program from Apollo to today’s exploration development. 2019 concluded the SKC Program’s 12th year distributing spacesuit-related knowledge to the NASA community, and it continues this effort today. Currently, the SKC Program has disseminated its spacesuit-related knowledge to over 3,400 classroom attendees and more than 32,100 online viewers. Use the links in Table 2 to access the program’s archived events. Table 2. Accessible Archived SKC Program DAA-Approved Event Files Domain Site Description URL Accessibility The NESC Academy provides online courses Public & NASA through which technical experts can teach critical https://nescacade community NASA competencies required to effectively accomplish my.nasa.gov/cata (requires NASA Engineering and the NASA mission. These courses provide an logs/cfd4cdc970 credentials to Safety Center opportunity to share critical knowledge with c046358afc1c2e view beyond (NESC) Academy broad audiences. Files with restricted access

5f72a0554d public available archived at this site require special credentials to events) be retrieved. The NEN provides access to technical lessons learned, Communities of Practice, and tools and NASA NASA resources. Interaction with subject-matter https://nen.nasa.g community Engineering experts and practitioners occur through ov/web/space- Communities of Practice. The site also allows (requires NASA Network (NEN) suits viewers to search many NASA repositories of credentials) interest and find tools and resources.

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IV. U.S. Spacesuit Knowledge Capture Program Emphasis The SKC Program has evolved into a tool to help educate the NASA community about legacy and current spacesuits. Although the program continues to host presentations, workshops, interviews, and vignettes, it will broaden its capability by capturing the anatomy of the next-generation spacesuit as it is being built.

A. Historical Emphasis Since the SKC Program’s infancy, it has focused heavily on inviting subject-matter experts (SMEs) into the classroom to share spacesuit-related knowledge. It has also captured thousands of legacy spacesuit-related files, preserved them in a database, and made them readily available to spacesuit professionals. This captured knowledge needs to be shared beyond the program’s limited distribution list and classroom audience to increase its usefulness. For this reason, the SKC Program is rigorously seeking strategies to methodically disseminate this knowledge to as many employees within the U.S. space industry who might apply it, as well as to college students and educators who will depend on it to help reach NASA’s future missions. When knowledge is shared, it increases opportunities to uncover and avoid obstacles and failures, recognize requirements, and identify possibilities. Therefore, while the SKC Program continues to capture and archive legacy spacesuit-related knowledge through hosting events, it is also preparing to capture more recently acquired knowledge – the current buildup of the next-generation spacesuit.

B. Future Emphasis The SKC Program’s future emphasis includes not only capturing spacesuit-related knowledge in a traditional way, such as SMEs sharing lessons through classroom events, it will also include real-time capture of the next-generation spacesuit buildup. The traditional classroom approach takes the SME out of their work environment and gathers them and the audience into a more static setting, away from the more dynamic laboratory and hardware ecosystem. However, the SKC Program will retain this methodology because of the valuable face-to-face interaction and learning that occurs. Additionally, surveys have revealed that the real-time interaction with the SME is important to capture the lessons learned and retain the knowledge. The SKC Program has a new opportunity to help capture more recently acquired knowledge – the current buildup of the next-generation spacesuit. NASA’s opportunity to capture the legacy spacesuit buildup was nonexistent. In the past, NASA wrote the spacesuit requirements, and a vendor designed, built, and assembled the suit in its facility. NASA was not able to capture this buildup because videography in a vendor’s facility was not allowed. Because the initial xEMU is being designed, built, and assembled in the JSC CTSD spacesuit laboratories, it is an opportune time to preserve details in the buildup of the new spacesuit from start to finish. Mechanisms such as special- event videography, photography, editing, and full production of the assembly will be used to capture this information. Gathering the details of the spacesuit buildup will be accomplished through capturing training, interviews, and photoshoots of the hardware, dynamic test operations, and hardware assembly. This will provide an active approach to capturing the knowledge in the engineer’s ecosystem. Existing photography and video archives may be used as well. To preserve this knowledge, the SKC Program will be fully engaged to help produce, organize, and archive the electronic legacy, capturing each vital step used to complete the spacesuit. Like a blueprint coming to life, this in- house real-time knowledge capture of the spacesuit buildup will complement the SKC Program archives in a monumental way.

V. Capturing the Anatomy of a Spacesuit For posterity and future NASA human space exploration, it is important to electronically record the buildup of the future spacesuit and tell the story of its evolutionary existence. To achieve this, the SKC Program will take a collage of various sources of knowledge previously captured and combine them with real-time capture of the new spacesuits being built in house to culminate into a complete story or stories about the anatomy of a spacesuit. These spacesuit stories will be used for educational purposes with the following objectives: 1) Establish educational content that becomes an organized, searchable library for the spacesuit community 2) Set capstone courses that help engineers transition toward being effective spacesuit engineers 3) Facilitate the training of spacesuit engineers and technicians 4) Help orient NASA engineers and technicians on the complexity of NASA’s next-generation spacesuit design 5) Facilitate the knowledge transfer across the xEMU team and EVA community 6) Create a subject-matter-focused document using the content within the “U.S. Spacesuit Knowledge Capture Series Catalog” 6

International Conference on Environmental Systems From the SKC Program’s inception to recent events, it continues to evolve as needed and as opportunities for progress are evident. The program will expand its responsibilities to help document the spacesuit buildup and interface with management to use the program’s recordings to its maximum capability. The SKC Program is researching ways for NASA employees and contractors to readily access the knowledge capture of the spacesuit buildup. The SKC Program is collaborating with the EVA Office to offer a central location where the EVA community can access this knowledge. This location is planned to be revealed in the future.

VI. Conclusion The spacesuit tells the story of our nation’s space travel and provides lessons learned through those experiences. With each piece of technology used, every vital test taken, and failures and successes identified and documented, each era of the spacesuit adds to the possibilities of future human space exploration. The SKC Program is a tool used to help capture, preserve, share, and apply this knowledge. The SKC Program continues to capture and disseminate spacesuit-related lessons by hosting courses, interviews, workshops, and vignettes. As spacesuit engineers and technicians who have decades of spacesuit-related knowledge continue to retire, their knowledge is retained within the SKC Program and disseminated within NASA and to academia and the public. These spacesuit lessons and stories give an account of past events that can contribute to the evolution and buildup of new spacesuits. The SKC Program is making its lessons to help train NASA spacesuit professionals. The program will collaborate with a cadre of SMEs to identify lessons that spacesuit engineers and technicians will be encouraged to review and learn. Because of the SKC Program’s reputation for identifying, preserving, and sharing valuable spacesuit-related lessons with spacesuit professionals, combined with the spacesuit buildup performed in house, it was offered the opportunity to capture this knowledge in real time. This opportunity will allow the SKC Program to broaden its involvement and orchestrate the capturing of the next-generation spacesuit buildup to train future suit designers and space explorers who will use these lessons to reach NASA’s objectives. As NASA strives to expand its human space exploration, the SKC Program remains flexible and ready to assist, expanding its library of spacesuit-related knowledge to help educate the space community and academia. Also, as the program evolves, it continues to write and share the story about one of our nation’s greatest technical gems – the NASA spacesuit.

Acknowledgments It takes a committed team to produce and disseminate the numerous SKC Program recordings that now reside on the NESC Academy and the NASA Engineering Network (NEN) Web sites. It will take even more effort to orchestrate the capturing of the next-generation spacesuit’s buildup. Although the SKC Program manager and administrator are readily known as the faces of the program, they appreciate and thank many professionals for their extraordinary help in the success of the program. These include Chris Hansen, who seized the opportunity to support and fund the SKC Program. Hank Rotter, who retired in 2019 and graciously continued to grant the SKC Program use of the NESC Academy’s Web site and expertise. Collaboration with Stephanie Sipila, EVA Office strategic planning and communication manager, has been instrumental in planning the future SKC Program emphasis. Videographers Jim Hansen, Matthew McGee, Roman Rama III, Britany Torabi, and Camille Ralston; NESC Academy producer and NEN community facilitator Alex Walker; and virtual knowledge specialist Daniel Hoffpauir produce the final products of the electronically recorded SKC Program events that are uploaded to the NEN and NESC Academy Web sites. Melissa Gore and Audrey Carter ensure the reservations of the videographers and classrooms. John Stoll helps reserve and prepare recording studios for the vignettes. Mike Rushing and Blake Dumesnil offer their photography skills for much of the program’s still images taken during its events with SMEs. Jeannie Corte is responsible for the program’s creative graphic designs. John Springhetti is dedicated to offering JSC IT support to the SKC Program. We appreciate the newcomers to the SKC Program, Diana Rodgers and Gordon Andrews, who have initiated the pathway to capture the spacesuit buildup. Our program is thankful for each SME who delivered an SKC Program event. With the contribution of these individuals, the SKC Program continues to write and tell the story of the spacesuit.

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