What question did this study set out to answer?

This research aims to develop a composite laminate for space suits that can withstand high impacts during lunar and Mars exploration.

May 9, 2026Open Access

Design and Fabrication of an Impact Resistant Composite Laminate with Shear Thickening Fluid Textiles for Space Suit Applications and their ISS Low Earth Orbit Studies on MISSE 15

Key Points

This research aims to develop a composite laminate for space suits that can withstand high impacts during lunar and Mars exploration.
Developed a hybrid composite structure incorporating shear thickening fluid textiles as core material.
Performed low velocity impact testing to optimize material properties within weight and thickness constraints.
Manufactured a prototype and evaluated panels after exposure to low Earth orbit during MISSE-15.
The new composite laminate successfully endured a 300 J impact without sustaining through-thickness damage.
Post-flight impact properties remained consistent with pre-flight testing results, affirming material durability.
No gas leakage occurred in the prototypes following impact tests and X-ray scans.

Abstract

With the upcoming lunar and Mars surface exploration a stronger, more resilient spacesuit is required to mitigate threats posed to astronauts. This includes the composite material in the spacesuit that is used in the brief and hard upper torso (HUT) portions of the suit. It was calculated that a 300 J impact could be experienced by the composite portion of the suit if an astronaut fell onto a rock or other object on the Martian surface. Previously studied composite materials could not withstand this level of impact, and failed at maximum impact energy of 70 J. We report the development of a new composite structure that uses shear thickening fluid (STF) enhanced textile layers as a core material in order to meet this high impact threat. A new hybrid composite sandwich structure with ultrahigh molecular weight polyethylene (UHMWPE) fabric treated with a low outgassing STF fluid as the core material was developed. Low velocity impact (LVI) testing was used to optimize the impact resistance of the material within weight and thickness constraints. The final optimized hybrid composite design was tested and shown to withstand a 300 J impact without sustaining through-thickness damage that would lead to gas leakage. Impacted panels were X-ray scanned and leak tested to confirm that no unseen damage throughout the structure was present. A prototype brief was manufactured using the optimized structure and proof tested at 16 psi. Panels using the optimized structure were then manufactured and then flown on the ISS and exposed to low Earth orbit as a part of the Materials International Space Station Experiment (MISSE)-15. The post-flight impact properties did not differ significantly from the pre-flight impact properties.

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