Collins Aerospace to deliver new spacesuits for ISS missions - Aerospace Manufacturing and Design

2022-12-21 16:27:27 By : Ms. kindy zhao

Described as the world's smallest spacecraft, new suits are designed by astronauts for astronauts.

Building on more than 50 years of experience developing spacesuits for NASA, Collins Aerospace (a Raytheon Technologies business), along with its partners ILC Dover and Oceaneering, was awarded a contract to design, develop, and demonstrate the next-generation spacesuit for the International Space Station (ISS). This is Collins' first task order under NASA's Exploration Extravehicular Activity Services, or xEVAS, contract which was awarded in May 2022.

"Our next-generation spacesuit was built by astronauts for astronauts, continuing Collins' long-standing legacy as a trusted partner of NASA's human space exploration," said Dave McClure, vice president and general manager, ISR & Space Solutions with Collins Aerospace. "Collins' advanced spacesuit technology will be used on the ISS, and we're prepared to continue keeping astronauts safe, connected, and ready no matter the mission."

Collins' next-generation spacesuit contains everything an astronaut needs to survive in the vacuum of space. Made up of more than 18,000 parts and with an interior volume the size of a small refrigerator, the suit provides oxygen, CO2 removal, electrical power, hydration, ventilation, thermal control, and communications.

"ILC Dover is proud to be working with a world-class team to design and manufacture the next generation of spacesuits for the ISS," said Corey Walker, CEO of ILC Dover. "Leveraging our decades of experience engineering the pressure garments for the Apollo missions and the ISS, our latest spacesuits will have the ability to be outfitted for missions from the ISS to the lunar surface and beyond."

Collins' next-generation suit is lighter weight and lower volume to improve astronaut efficiency, range of motion, and comfort. Designed to fit nearly any body type, it also has an open architecture design which allows the suit to be easily modified as missions change or become more advanced.

The award – the second under NASA's Exploration EVA Services contract – is for design and development of a next-generation spacesuit and support systems. The task order has a base value of $97.2 million.

Collins Aerospace will complete a critical design review and demonstrate use of the suit on Earth in a simulated space environment by January 2024. NASA will have the option to extend the contract for a demonstration with agency crew members outside the space station by April 2026.

With this second award for a new suit and system, NASA is another step closer to a replacement for the current design used by NASA astronauts for decades during space shuttle and space station missions. The new suit will support continued station maintenance and is crucial to future Artemis missions to the Moon in preparation for Mars.

"We look forward to obtaining another much-needed service under our contract," said Lara Kearney, manager of the Extravehicular Activity and Human Surface Mobility Program at NASA's Johnson Space Center in Houston, which manages the spacesuit contract. "By working with industry, NASA is able to continue its over 22-year legacy of maintaining a presence in low-Earth orbit."

Under the indefinite delivery, indefinite quantity contract, both Collins Aerospace, as well as Axiom, which was awarded an initial task order award for Artemis suits, provided proposals to meet both station and Artemis requirements. Both vendors will continue to compete for future task orders which include recurring services for station spacewalks and moonwalks beyond Artemis III.

Collins will be responsible for the design, development, qualification, certification, and production of its station spacesuits and support equipment to meet NASA's key requirements. The agency will continue to maintain the authority to manage astronaut training, spacewalk planning, and approval of the service systems.

"We are extremely excited and proud to be part of the Collins team, helping to successfully develop and deploy critical U.S. EVA space exploration capability," said Phil Beierl, senior vice president, Aerospace and Defense Technologies, Oceaneering. "Our staff brings outstanding spacesuit systems engineering and integration expertise to this task. We look forward to leveraging our portable life support and pressure garment subsystem technologies, as well as our crew training and mission operations knowledge to support the Collins team."

ILC Dover spacesuits have been worn during more than 250 space flights, six moon landings, and over 3,000 hours of spacewalks without a single failure. ILC Dover has developed two commercial suits, Sol, a Launch, Entry, and Abort (LEA) suit, and Astro, an extravehicular activity (EVA) and planetary exploration suit.

Oceaneering Space Systems, a business within Oceaneering's Aerospace and Defense Technologies segment, specializes in engineering for harsh environments from sea to space with complete turnkey design, development, manufacturing, certification, maintenance, testing, and sustaining engineering for space-based robotics and automation, satellite servicing tools and equipment, human space flight systems, and thermal protection systems.

Start 2023 off with insights from Terry Wohlers about what's new in additive manufacturing.

As the additive manufacturing (AM) industry continues to mature, many companies are looking to AM for where it can help shorten lead time and create new opportunities. However, AM is not a one-size-fits-all solution and still isn’t right for mass production in many areas. With AM being used for an array of applications, it can complement a company’s capabilities for some production applications.

Register for this free webinar - Advances and challenges in additive manufacturing - taking place on Wednesday, Jan. 11, 2023 12:00PM ET.

Learn about many of the most interesting developments in the industry, while recognizing the challenges that many face. Hear how AM can be scaled for mass production – and where that’s happening today. And find out some of the most thought-provoking trends in the AM industry.

Company continues to grow and invest in Kentucky machine tool production operations.

To support the production of yet another new Kentucky-designed and built line of machine tools, Mazak has expanded its Florence manufacturing campus with the addition of a new SYNCREX Assembly Plant. The 27,000ft2 state-of-the-art building combines engineering, production, and applications support for the company’s recently launched SYNCREX Series of Swiss-style machine tools designed specifically for precision high production of small parts.

With an output capacity of up to 10 machines per month, the SYNCREX building features all the necessary overhead cranes and equipment its employees need to produce 16 different models within the SYNCREX Series for serving the North American market. The machines come in four barstock capacities (20/25/32/38) and four different axis configurations up to a 9X model with full B-axis contouring capabilities. Production flow through the building starts with a machined base that progresses through assembly operations and on to alignment, testing, inspection, and runoff procedures prior to shipping.

“While the building’s name is the SYNCREX Assembly Plant, a lot more than just assembly happens there,” said Kevin Sekerak, plant manager at Mazak. “Within the new building’s production flow, we’ve incorporated applications support, which is extremely critical for this particular type of machine. That support entails integrating various forms of automation and other ancillary systems together with the machines, then proving them out to make sure they all operate to customer performance requirements and specifications. Often, applications specialists will work side by side with assembly technicians during customer runoffs of a machine.”

The sliding-headstock SYNCREX machines are all constructed on Mazak High Damping Composite Castings (HDCC) produced in the United States and machined at Mazak Kentucky. The unique high rigidity base provides greater vibration damping characteristics, less thermal growth, and greater part surface capabilities when compared to a cast iron base machine. Mazak also produces SYNCREX spindles, headstocks, sheet metal, and many other key components in Kentucky to ensure every machine provides the highest possible accuracy and repeatability.

Launching the all-new SYNCREX line, Mazak further expanded its machine tool technology portfolio – models designed and produced in Florence, Kentucky – including the company’s Ez Series of machines.

Mazak maintains eight Technology Centers across North America to provide local hands-on applications, service, and sales support to customers.

Focus on two 19-to-30-seat designs for hybrid electric and hydrogen electric propulsion.

Embraer revealed new aircraft concepts as part of the company’s progress report on Energia – Embraer’s initiative to get the aviation industry to net-zero emissions by 2050.

A year on from Embraer’s Sustainability in Action event, which detailed the study of four new aircraft concepts powered by new technologies and renewable energies, the company has been focusing on two 19-to-30-seat designs for hybrid electric and hydrogen electric propulsion. Guided by the company’s 50-year technical expertise, external inputs from airlines, and joint studies with engine original equipment manufacturers (OEMs), these two approaches to net-zero offer a technically realistic and economically feasible pathway to net-zero, according to Embraer.

Energia Hybrid (E19-HE and E30-HE) – revealed as a 9-seater in 2021, Embraer is exploring a 19- and a 30-seat variant:

Energia H2 Fuel Cell (E19-H2FC and E30-H2FC) – revealed with 19 seats in 2021, Embraer is exploring a 30-seat variant:

While still at the evaluation phase, the architectures and technologies are being assessed for technical and commercial viability. The Energia Advisory Group has also been launched to harness input and collaboration from partner airlines.

Arjan Meijer, president and CEO, Embraer Commercial Aviation, said, “I believe we have set bold but realistic goals for these concepts to come to market. Since we announced our Energia concepts last year, we have been busy evaluating different architectures and propulsion systems. These efforts have resulted in the updates of our concepts that we are sharing with you today. A number of airlines are part of our Energia Advisory Group, the experience and knowledge they bring to the study will be key to accelerate to the next phases.”

“As new propulsion technologies will be first applied on smaller aircraft, Embraer is in a unique position. The 19- and 30-seaters are sensible starting points for focused studies since they are likely to present earlier technical and economical readiness,” said Luis Carlos Affonso, Sr. VP of engineering, technology and corporate strategy for Embraer. “While the challenges of net-zero are significant, in less than 25 years our commercial aircraft have already reduced fuel burn and CO2 emissions by almost 50% on a seat/mile basis, using only conventional fuels and propulsion – I’m convinced net-zero is a goal we can reach.”

The event ‘Energia – The shape of things to come’, available on Embraer’s YouTube channel https://youtube.com/@Embraer, was broadcast live from Amsterdam and Sao Jose dos Campos. As well as presentations from Embraer’s chief engineer, and Commercial Aviation CEO, it features a 360° tour of two of the concepts Embraer is focusing on - Energia H2 Fuel Cell and Energia Hybrid Electric.

Airline is also purchasing 100 737 MAX jets, exercising 44 existing options and placing 56 new orders.

United Airlines is investing in its future fleet with an order for 100 Boeing 787 airplanes, with the option to purchase 100 more. The deal is the largest 787 Dreamliner order in Boeing history. United is also purchasing 100 737 MAX jets, exercising 44 existing options and placing 56 new orders.

The combined value of the orders likely exceeds $40 billion.

"United emerged from the pandemic as the world's leading global airline and the flag carrier of the United States," said United CEO Scott Kirby. "This order further solidifies our lead and creates new opportunities for our customers, employees and shareholders by accelerating our plan to connect more people to more places around the globe and deliver the best experience in the sky."

The airline's current orders for Boeing jets have surpassed 530, including more than 430 737 MAX airplanes.

"With this investment in its future fleet, the 737 MAX and 787 will help United accelerate its fleet modernization and global growth strategy," said Stan Deal, president and CEO of Boeing Commercial Airplanes. "The Boeing team is honored by United's trust in our family of airplanes to connect people and transport cargo around the world for decades to come."

The 787 Dreamliner offers 25% improvement in fuel use compared with the airplanes it replaces, depending on the configuration.

The 737 MAX family reduces fuel use and CO2 emissions by 20% compared to the airplanes it replaces, depending on the configuration.