US Military Aviation
Flight Helmets
SPACE


Following the Soviet space program's launch of the world's first man-made satelite (Sputnik 1) in 1957, the United States government was alarmed by the perceived thread to U.S. security and technological leadership. In early 1958 representatives of the government, the military and aircraft industry agreed that a new federal agency was needed to conduct all non-military activity in Space. On October 1958 NACA ceased to exist, being transformed into a new civilian organization that would deal not only with aeronautics but astronautics- space flight- as well. That organization was named National Aeronautics and Space Administration (NASA). Only few days after NASA opened for business, its Administrator announced the inception of the first U.S. man-in-space program which was later named Project Mercury.
If the human beings are to survive in the deadly environment that is Space, they must surround themselves with something that duplicate the various vital functions of the Earth's atmosphere as breathable air, pressurization, temperature and humidity control and exhaled carbon dioxide removal. These functions are provided by a multilayer garment and relevant helmet that insulates the astronaut from the space environment or, as for the partial and full pressure suits used in the high altitude flight provides body protection in case of spacecraft sudden leak or decompression.

PROJECT MERCURY

The objective of Project Mercury was to get an American into space and return him safely to earth. The program was divided into two phases. In phase one, the suborbital phase, an astronaut was simply launched into space, in a balistic flight without reaching the orbital speed and altitude. In the second phase, the astronaut actually went into orbit around the earth. On 5 May 1961 Alan Shepard Jr was the first American in space at an apogee of 107 miles. A second sub-orbital space flight was succesfully performed by Gus Grissom even if the capsule sank in Atlantic ocean during the retreival phase. On 20 February 1962 John Glenn was the first American to orbit the earth followed by the others first selected U.S. astronauts Scott Carpenter, Walter Schirra and L. Gordon Cooper.
The very first suit and helmet worn by Americans in space was based on the USN Mark IV high altitude full presure suit with some design changes in hemet oxygen system, communications and suit general layout.


The NASA original seven astronauts wearing the first model Project Mercury full presurized flight suit. Contrary to popular thought, the space suits of Projet Mercury were only for emergencies, being not pressurized during flight.(NASA)
The helmet worn by the first four Americans in space was based on the USN Mark IV high altitude model produced by B.F. Goodrich in 1961. A different oxygen system was employed which eliminates the face seal separating the face and the rest of the head as on the Mark IV. (Schiffer Publishing Ltd.)

Virgil "Gus" Grissom before the second suborbital Mercury mission (MR-4). Helmet, which had to fit perfectly, accounted for about half the suit's cost. (NASA)
In 1962 a helmet modified with a mechanical visor sealing system was used by Astonaut Gordon Cooper. No dedicated nomencalture was given to the Mercury space helmets and suits but they took reference from the specific mission (MR-3, MR-4, MA-6, etc...). (Schiffer Publishing Ltd.)

Gordon Cooper made 22 orbits wearing his MA-9 suit. Cooper's suit and helmet reflected many changes since the early Mercury flights. (NASA)
GEMINI PROGRAM

The objective of the Gemini program were more complex than those of the Mercury program. All of the major components of the Gemini program were designed to test procedures that could be utilized in deveoping the subsequent Apolo program. These included rendezvous and docking in space, extravehicular activity (space walks) and extended-duration flight that would be up to3 to 10 times as long as the longest Mercury flights. The first manned Gemini flight came on 23 March 1965 with Mercury veteran Gus Grissom and newcomer John Young at the controls.
New Designs for Gemini garment were introduced. Mission-related requirements called for 14 days' continuous wear, pressurized mobility compatible with spacecraft crew-station design, pressurized operation in extavehicular activity (EVA) and unpressurized comfort and mobility.
The G3C helmet developed by David Clark Co. Inc. had a fiberglass shell with plexiglas visor and liner inside for impact and shock absorption. It was used with the G3C suit for intravehicular use. (Schiffer Publishing Ltd.)

Astronaut Ed White wearing G4C extravehicular helmet and suit. The G4C incorporated a triple lens shield visor assembly for visual, thermal, impact, and micrometeoroid protection. The outermost shield , a gold-coated sun visor, protected the eyes from full exposure to unfiltered direct sunlight (NASA)
Modified from the G3C, the G4C helmet was used as standard helmet on several Gemini missions. For intravehicular activity (IVA) the two EVA visors were simply omitted. (Schiffer Publishing Ltd.)

The versatile, lightweight Gemini G5C space suit was worn by the Gemini 7 crew, Borman and Lovell. It had a soft cloth-shell, collapsible helmet with polycarbonate visor, fastened with a pressure-sealing zipper. A rigid helmet, worn underneath, provided impact and shock protection.(NASA)
Light weight helmet part of the G5C spacesuit. This image shows the Borman's back up suit for the Gemini 7 mission. (Smithsonian National Air and Space Museum Collection)

This protective helmet was possibly worn by Frank Borman during the launch of the Gemini 7 mission in December, 1965. The helmet was fitted with communications equipment, and was worn under the hood-like, integrated helmet of the G5C spacesuit.
Gemini 7 astronauts James Lovell and Frank Borman after their 330 hours and 36 minutes long duration mission wearing the lightweight G5C space suit. (NASA)

Astronaut Gordon Cooper on Gemini 5 with G4C helmet and space suit.(NASA)
NASA Full Pressure helmet GH-4C-5 developed for Gemini program. (Steven Wilson)

APOLLO PROGRAM

Following the the Mercury and Gemini programs, the Apollo program was originally developed to do interesting work in space and possibly put men around the moon. After the President John F. Kennedy's announcement on May 25, 1961 the Apollo became a program to land men on the Moon. After eight years of preliminary missions, including NAS's first loss of astronauts with the Apollo 1 launch pad fire, and the first spacecraft to orbit the Moon (Apollo 8), the Apollo program achieved its goals with Apollo 11 which landed Neil Armstrong and Buzz Aldrin on the Moon's surface on July 20, 1969. This first Moon land mission was followed by other five succesfully moon landing and one near-disaster of Apollo 13.
New design of space garments for Apollo program were developed with new materials, improvement in confort and mobility, liquid cooling system and meteroid protection to meet the NASA requiements both for IVA and EVA activity and for the lunar suit system, officially designated Extravehicular Mobility Unit (EMU).
Apollo 1 astronauts Virgil I. "Gus" Grissom, Edward H. White II, Roger B. Chafee wear A-1C Block 1 suits for mission simulation test. Produced by David Clark Co. Inc. the A-1C helmet is a Gemini G3C modified with a large protective visor shield. This crew died during Apollo 1 fatal fire in 1967. (NASA)

Apollo 9 astronaut David Scott during EVA activity wears the A7L EVA suit with a red colored plastic protective shell over the polycarbonate helmet dome with and external gold tinted visor. (NASA)
Apollo 11 astronaut Edwin E. Aldrin Jr. on moon Tranquility Base with A7L suit and helmet with beta cloth cover. (NASA)

Apollo 13 astronaut James Lovell with A7L helmet. The A7L is essentially a one-piece, fixed, polycarbonate dome with a head pad in the rear. For use on the lunar surface, a gold-tinted visor, white thermal cap, and adjustable eyeshades were added. (NASA)
A7LB Apollo pressure bubble of the Apollo 15 Astronaut Alfred M. Worden (Smithsonian National Air and Space Museum Collection)

Apollo 15 astronaut Davis Scott during training at Kennedy Space Center with complete A7LB suit and helmet. Starting from the Apollo 13 red band was added above the elbows, below the knees and on the helmet of one of the space suit to easily designate the commander. The helmet LEVA outer protecive shell now contained provisions for sun shade on both sides and in the center, which could be adjusted to various heights. (NASA)
Apollo 16 astronaut John W. Young on moon surface with A7LB suit and helmet. Since the first lunar mission several modifications and improvements have been introduced on A7LB Extravehicular Mobility Unit . (NASA)

A7LB Lunar Extra vehicular Visor Assembly of Eugene Cernan, Apollo 17 (Smithsonian National Air and Space Museum Collection)
The inner Communication Carrier Assembly nicknamed the "Snoopy Cap" used with A7L suit was designed and produced by David Clark Co. Inc. (Schiffer Publishing Ltd.)
X-20 DYNA-SOAR

Based on a WWII German bomber projet to create a rocket-powered bomber that could travel vast distance by gliding to its target after being boosted to high speed and high altitude, the X-20 Dyna-Soar (Dynamic Soarer) was a United States Air Force program to develop a spaceplane that could be used for a variety of military missions, including reconnaissance, bombing, space rescue, satellite maintenance, and sabotage of enemy satellites. The program ran from October 1957 to December 1963, and was canceled just after spacecraft construction had begun.
Unlike the other spacecraft such as Mercury, Gemini, Apollo Dyna-Soar was intended to glide to earth under the control of the pilot and land at a pre-selected site, rather than simply falling to earth in a ballistic manner. This made Dyna-Soar far more advanced, in many ways, than the other human spaceflight missions of the period; it is one of the great "what if" projects of early spaceflight. In time, data collected during the X-20 program would prove useful in designing the Space Shuttle.
The X-20 suit was little more than modified high altitude, David Clark Company military aviation pressue garments A/P22S-2 with aluminized cover layer, and included boots and gloves. The bubble helmet was supported by the internal suit structure rather than separately joined and offered good visibility.
X-20 first helmet design. The space helmet for the X-20 was designed to permit all necessary head movement from within. This would reduce neck strain during launch. The suit and helmet design contarctor was awarded to the David Clark Co. Inc. (Schiffer Publishing Ltd.)

Because the X-20 was to have an ejection seat, the second type of helmet was more wind-resistant, and lighter. Anti-suffocation valve was also prsent on lower right side. (Schiffer Publishing Ltd.)
Communication helmet was padded and had microphone mounted uniquely on the chin cup. This inner helmet was a universal fit with velcro adjustments. (Schiffer Publishing Ltd.)

The X-20 suit was little more than modified high altitude, David Clark Company military aviation pressue garments A/P22S-2 with aluminized cover layer, and included boots and gloves.
Beautiful specimen of the later X-20 pressure Flight Helmet
Manned Orbiting Laboratory (MOL)

The Manned Orbiting Laboratory (MOL) was part of the United States Air Force's manned spaceflight program, a successor to the cancelled X-20 Dyna-Soar project. It was announced to the public on the same day that the Dyna-Soar program was cancelled, December 10, 1963. Also codenamed Dorian and given the designation KH-10, the MOL was intended to be a space station used for reconnaissance purposes. It was derived from NASA's Gemini program. The project was cancelled on June 10, 1969 before there were any operational flights.
There was one test flight of an MOL mockup that was constructed from a Titan II propellant tank. The Gemini 2 spacecraft was re-flown on a 33-minute sub-orbital test flight. After the Gemini was separated for its sub-orbital reentry, the MOL mockup continued on into orbit and released three satellites. A hatch was installed in the Gemini 2 heat shield to provide access to the MOL and was tested in the sub-orbital reentry.
The first type of MOL suit was designed to support launch/re-entry and early emergency Extra-Vehicular Activity (EVA). David Clark, International Latex, AiReseach and Hamilton Standard developed prototypes prior to the 1967 production contract competition. In 1967-68, the USAF competed an exclusively EVA suit-system development. The Integrated Maneuvering Life Support System (IMLSS) design was the result. IMLSS could operate on an umbilical from MOL or disconnect and fly independently from the station.
The first type of MOL suit (Manned Orbiting Laboratory Suit) was designed to support launch/re-entry and early emergency Extra-Vehicular Activity (EVA). David Clark, International Latex, AiReseach and Hamilton Standard developed prototypes prior to the 1967 production contract competition. Hamilton Standard won the manufacturing order and fabricated at least 22 MOL suits before the program was cancelled in 1969. The suit designation was MH-7. The flight suits were to have helmets with outer sun visors and cover-garments featuring aluminized Mylar insulation with white outer fabric made of fiberglass impregnated with Teflon. (USAF)

For the Manned Orbiting Laboratory (MOL) space station, the U.S. Air Force recognized that existing launch/re-entry and Extra-Vehicular Activity (EVA) type suits had limited EVA ability. In 1967-68, the USAF competed an exclusively EVA suit-system development. The Integrated Maneuvering Life Support System (IMLSS) design was the result. IMLSS could operate on an umbilical from MOL or disconnect and fly independently from the station.
The MOL IEVA suit final configuration get the designation MH-8. The MOL program was cancelled in 1969 before the prototype gained its thermal outer covers. IMLSS packaging and integration experience greatly influenced what is now Hamilton Sundstrand in the design of the Shuttle Extravehicular Mobility Unit that still serves NASA today. (USAF)

The MOL Helmet was a simple polycarbonate bubble similar to those eventually used during the Apollo program. The main differences between the MOL and Apollo pressure bubbles were that on the MOL helmets, the non-vision areas were painted white to provide thermal insulation, and they had a higher air flow in the vent duct system. This prevent fogging, and permitted improved carbon dioxide removal. (Smithsonian National Air and Space Museum Collection)
Skylab Medical Experiments Altitude Test (SMEAT)

A Skylab Medical Experiments Altitude Test was held for 56 days beginning July 26, 1972 to obtain baseline medical data and evaluate medical experiment equipment planned for use in the upcoming Skylab program. Astronaut Robert L. Crippen, William E. Thornton and Karol J. Bobko partecipated in the test in the 20-foot altitude chamber at the Manned Space Center in Houston. The test ended September 20, 1972.
The SMEAT crew entering the Skylab simulator at the beginning of their 56 day "flight". They were equipped with modified BPH-2 (visor and relevant housing removed) and MS22001 or MBU-5/P oxygen masks. (NASA)
SKYLAB

Skylab was the name of America's first orbiting space station. It used hardware developed for the Apollo moon landing including the command module and the Saturn V rocket. Three crews sailed on Skylab on the longest space voyager up to that time lasting 28, 59, and 84 days each. Unlike the MOL, the objectives set for Skylab were scientific, not military. Experiments conducted on Skylab laboratory covered several areas of research as medical test, micro-gravity experiments, earth and space observation and study, solar astronomy, technical experiments, and extavehicular activity (EVA).
The Skylab astronauts wore modified Apollo A7LB pressure suits during launch and EVA activity. The Skylab suit included mobility joints at the knees, wrists, shoulders, elbows, ankles, and thights to ensure normal body flexture. In addition to a new lightweight integrated thermal micrometeoroid garment covering the Pressure garment, astronauts wore the Skylab extravehicular visor assembly (SEVA), which included a shell over the helmet. There were two visors, two side eyeshades, and a center eyeshade mounted in the outer shell.
Skylab 2 astronaut Jack Lousma with A7LB suit and helmet modified with a plastic protective shell and the extravehicular visor assembly SEVA. (NASA)

On Skylab was tested around the spacious workshop the automatically stabilized astronaut maneuvering unit (AMU). During these test the astronauts wore protective fibergalss helmet with incorporated the communicaton system. (NASA)
APOLLO-SOYUZ

The Apollo -Soyuz Test Project (ASTP) was a projet to demonstrate a new avenue of cooperation between the Unided States and USSR. An American Apollo and a Soviet Soyuz, launched separatelly, would dock in space. Connected by a unique, jointly designed docking module, the two crews would visit one another in orbit, performing symbolic, scientific, and applications activities. The Apollo-Soyuz Test Project took place July 1975.
Since extravehicular activity had been excluded from this joint mission, the astronauts needed space suit only for launch, orbital insertion, docking and undocking exercises, and return trip. NASA chose a sophisticated modification of the A7L model suit with an intravehicular cover layer, but gave it an A7LB designation.
Apollo-Soyuz astronaut Vance Brand and cosmonaut Valery Kubasov with A7L type Communications Carrier Assembly. (NASA)
SPACE TRANSPORTATION SYSTEM (Space Shuttle)

The Space Transportation System is a winged orbiter, designed to be capable of at least 100 missions. it is launched by its own three rocket engines. Two solid-fuel rocket boosters supplement the launch of the 91,000 kg orbiter. The Space Shuttle Orbiter is designed to be piloted by a flight crew of two but capable of routinelly carring seven or more Mission Specialist or Payload Specialist to perform services such as satellite deployment, satellite rescue missions, and repair in low earth orbit. At the end of the mission the Space Shuttle is glide back into the atmosphere unpowered, landing like an airplane. The craft would be ready for another mission after servicing and refurbishment. In the first four test flight the crews were provided with special emergency equipment designated as Emergency Escape Suit (EES) that was not standard on later flights. From the fifth to the twenty-fifth Shuttle flights, there had no means for crew escape during flight. Ejection seats and pressure suits were removed. However, many changes in safety practices were made following the loss of Challenger such as bail out mode with an escape telescoping pole, and postlanding egress slide. More importantly, astronauts have returned to wearing the special one-piece partial (later full) pressure launch/entry suits (LES) similar to those worn aboard the first four Shuttle flights.
For very long duraton EVA missions the Extravehicular Mobility Unit (EMU) was adopted for Space Transportation System in 1982. The EMU is capable of providing life support for astronauts working in the space environment for up to eight hours. The EMU can be also equipped with the Simplified Aid for Extravehicular activity Rescue (SAFER) which is a small, self-contained, propulsive backpack device that can provide free-flying mobility for a space-walker to be used in the event that a tethered astronaut breaks away during an EVA. Extravehicular activity beyond the near vicinity of the spacecraft, such as satellite retrieval, are facilitaded by the Manned Maneuvering Unit (MMU) a 24 thrusters chair that allow the astronaut to hold a staton-keeping positon or maneuver up, down, sideways, in reverse, or forward by operating hand controlson the end of each armrest.
Used in the first four STS space test flight, the S-1030A full pressurized suit was a modified S-1030 used in the SR-71. Although designated the S-1030A, none of the modifications effect the helmet. it remains unchanged from the S-1030. (NASA)


The Space Shuttle was intended to be used without pressure suit because these precaution were considered no longer necessary. Astronaut Anna Fisher in a Orbiter simulator wearing an early proposal of launch/re-entry helmet similar to the cranial protective headset used by army tank crew. (NASA)
Training model of Personal Rescue Enclosure (PRE). The "real rescue ball" was made from triple layered synthetic fabric. It zips together and was then inflatted. Inside the astronaut had a self-contained life-support system. Before the Shuttles became operational, this overall rescue concept was found to be impratical, thus the PRE never reached flight. Nevertheless, the PRE lives on as an evaluator of astronaut capabilities in the selection process for astronaut candidates.(NASA)

The fifth STS flight was the first mission considered to be operational. That mission, and the following twenty through the "Challenger" tragedy in1986, the STS was considered safe enough not to need pressure suits. The requirement for a non pressurized helmet resulted in a helmet heavily based upon the HGU-20/P "Clamshell". (NASA)
The Launch/re-entry helmet (LRH) produced by Gentex using many of the same parts as the HGU-20/P, the LRH has a shell constructed not of fiberglass but of ligher carbon fiber. The oxygen regulator is different and the Gentex LRH has two microphones. (Schiffer Publishing Ltd.)

For very long duration EVA missions the Extravehicular Mobility Unit (EMU) was adopted for STS in 1982. Produced by Hamilton-Standard, the rigid helmet is constructed of polycarbonate. An inner Communication Carrier Assembly almost identical to the A7L is used. A gold tinted visor and adjustable eyeshades are also used. Four small halogen lights are mounted on the top sides of the helmet. (NASA)

Extravehicular activity beyond the near vicinity of the spacecraft, such as satellite retrieval, are facilitaded by the Manned Maneuvering Unit (MMU) a 24 thrusters chair that allow the astronaut to hold a staton-keeping positon or maneuver up, down, sideways, in reverse, or forward by operating hand controlson the end of each armrest. (NASA)
As a result of the re-evaluation program following the "Challenger" tragedy, NASA returned to using a launch and re-entry pressure suit for all Space Shuttle missions. Produced by David Clark Co. Inc. the 1988 model S-1032 was a partial pressure suit (LES) used with carbon fiber helmet rotated on its neck mounting ring yet is large enough to permit limited head movement from within. The blue color suits are training models not used for flight. (NASA)

Space Shuttle S-1032 partial pressure suit (LES) and relevant helmet. The large polycarbonate visor is mechanically sealed by way of a tension bar activated cam system much like used on the S-1030 helmet. Dark tinted visor can be positioned as needed. (NASA)
The Space Shuttle S-1035 full pressure suit (ACES) use the same typology of helmet as the S-1032. The large helmet design ease stress on the astronauts' neck during launch when the G-force, sustained for several minutes, makes head movement very difficult. Inner communication helmet has extra microphone for backup. (NASA)

The EMU can be also equipped with the Simplified Aid for Extravehicular activity Rescue (SAFER) which is a small, self-contained, propulsive backpack device that can provide free-flying mobility for a space-walker to be used in the event that a tethered astronaut breaks away during an EVA. (NASA)
Communication Carrier Assembly CCA with chin strap and double microphone used with S-1032 (LES) and S-1035 (ACES) Space Shuttle suits. (NASA)

The first type of white CCA used on the LES and ACES suits was later replaced with a new "Russian style" Communication Carrier Assembly. (NASA)
INTERNATIONAL SPACE STATION

The International Space Station (ISS) is a joint project of five space agencies: the National Aeronautics and Space Administration (United States), the Russian Federal Space Agency (Russian Federation), the Japan Aerospace Exploration Agency (Japan), the Canadian Space Agency (Canada) and the European Space Agency (Europe). The Brazilian Space Agency (Brazil) participates through separate contract with NASA. The Italian Space Agency similary has separate contracts for various activities, that are not done in the framework of ESA ISS works (where Italy also fully participates). In many ways the ISS represents a merger of previously planned independent space stations: Russia's Mir 2, United States' Space Station Freedom and the planned European Columbus and Japanese Experiment Module. Due to the ISS, there is a permanent human presence in space, as the ISS' crew size has been at all times at least two since the first permanent crew entered the ISS on November 2, 2000. It is serviced primarily by the Soyuz , Progress spacecraft units and Space Shuttle. The ISS is currently still under construction with a projected completion date of 2010. At present, the station has a capacity for a crew of three. So far, all permanent crewmembers have come from the Russian or United States space programs. The ISS has however been visited by astronauts from a large number of other countries and was also the destination of the first space tourists.
For very long duration Extravehicular activity the ISS crew are equipped both with Russian EVA suit and the last version of United States Extravehicular Mobility Unit which can be integrated with SAFER device.
Russian Cosmonaut on Space Station is wearing a NASA extravehicular Mobility Unit. (NASA)

NASA EMU stowed inside the International Space Station. (NASA)
NASA astronaut with EMU during EVA outside the Internatonal Space Station. (NASA)
SPACE SHIP ONE

The Scaled Composites Model 316 Space Ship One is an experimental air-launched suborbital spaceplane that uses a hybrid rocket motor. This private-venture craft is designed to leave the earth's atmosphere and enter in space defined as altitude of 100 Km (62 miles). The design features a unique "shuttlecock" reentry system whose half-delta wing folds upward at the center of its twin tail booms; this increases drag while remaining stable. The Space Ship One (SS1) exceed an altitude of 328.00 feet on October 4 2004. New funding comes with the jointly between Virgin Galactic and Scaled Composites for the new Spaceship company who is to fund the successor Space Ship Two (SS2) and White Knight Two (WK2).
During the flight the test pilots wore customized flight helmet and oxygen mask. Gentex HGU-55/P flight helmets and modified oxygen masks MBU-20/P with additional oxygen hose were worn during SS1 space flights.
Custom Gentex HGU-55/P as worn by Space Ship One pilot Mike Melvill on the first privately founded flight into space. (Gentex)

Space Ship One pilot with customized Gentex HGU-55/P. A modified MBU-20/P oxygen mask was used during the space flight of Space Ship One (Discovery Channel Production)
ORION

MACES (Modified Advanced Crew Escape Suit) is a suit intended for use in Orion. Because of mass and volume constraints, NASA wanted to be able to use ACES (the suit intended for ascent and entry during Space Shuttle missions) both for ascent/entry periods of Orion missions and also for EVA (space walks). MACES, therefore, is a hybrid of the orange Space Shuttle escape suit and the white ISS EVA suit.
The suit has a new cooling garment and new bearings in the joints. It also uses the gloves and boots from the ISS EVA suit (EMU). It looks like it will be suitable for EVAs up to about four hours. And, since that is a much longer period that the crew have to keep the visor closed while in the vehicle, a drink bag has also been added.
NASA MACES space suit developped to be used on Orion spacecraft. (NASA)

MACES space suit is a hybrid of the orange Space Shuttle escape suit and the white ISS EVA suit.
STARLINER

The Boeing Company has developped its new pressure garment that NASA crews and commercial passengers will wear for flights on board its CST-100 Starliner spacecraft, starting as soon as 2018. The suit, which features Reebok-inspired footwear and touchscreen compatible gloves, was designed to be lighter and less bulky than prior launch and entry outfits.
The full suit, which includes an integrated shoe, weighs about 20 pounds with all its accessories – about 10 pounds lighter than the launch-and-entry suits worn by space shuttle astronauts. The new Starliner suit's material lets water vapor pass out of the suit, away from the astronaut, but keeps air inside. That makes the suit cooler without sacrificing safety. Materials in the elbows and knees give astronauts more movement, too, while strategically located zippers allow them to adapt the suit's shape when standing or seated.
Boeing pressure suit to be used on CST-100 Starliner spacecraft. (Boeing)

The Boeing Starliner pressure suit incorporates a polycarbonate visor, fastened with a pressure-sealing zipper. A rigid helmet, worn underneath, provided impact and shock protection. (Boeing)
The Boeing pressure suit Starliner is worn with a lightweight helmet with the communication assembly. (Boeing)

CREW DRAGON

The SpaceX Company has developped its new IVA suit that NASA crews and commercial passengers will wear for flights on board its Crew Dragon spacecraft.The majority of the helmet is 3D printed and SpaceX has used that capability to directly integrate valves, a number of complex mechanisms for visor retraction and locking, microphones, and even air cooling channels into the helmet’s structure. The fact that it looks so minimal and simple is only the case after a huge amount of effort was directed at simplifying the user experience for astronauts and ensuring extremely reliability and intuitive control and actuation mechanisms throughout. One of the most difficult challenges of the spacesuit’s design was bringing all necessary external connections (power, water, air, etc) into one single umbilical panel located in the middle of the suit’s right thigh, meaning that astronauts will only have to worry themselves with a single, simple connection point once inside Crew Dragon. Additionally, SpaceX wanted to ensure optimal mobility inside Crew Dragon’s cabin while still allowing for operations in the event of extreme emergencies and loss of cabin pressure on-orbit. As a result, the spacesuit has been designed to allow Dragon’s crew to work in even the most extreme emergency conditions, up to and including hard vacuum. The suits would still require some sort of backpack if they were ever needed for actual spacewalks outside the capsule or ISS, so that functionality is off the table for now.
SpaceX IVA suit to be used on Crew Dragon spacecraft. (SpaceX)


directly integrate valves, a number of complex mechanisms for visor retraction and locking, microphones, and even air cooling channels into the helmet’s structure (SpaceX)
SpaceX wanted to ensure optimal mobility inside Crew Dragon’s cabin while still allowing for operations in the in the event of extreme emergencies and loss of cabin pressure on-orbit. (SpaceX)