Tag: Collins Aerospace

Inspector General: The state of NASA’s spacesuits on ISS is becoming critical

1:28 pm

NASA's failed spacesuit
NASA’s failed Moon spacesuits

A new NASA inspector report issued today [pdf] has found that the single contractor NASA uses to maintain the spacesuits on ISS, Collins Aerospace, has increasingly been unable to do the job, and NASA has no alternative contractor to turn to. From the report’s executive summary:

We previously reported on NASA’s spacesuit management in 2017 and 2021, finding that the Agency faced a wide array of risks to sustaining the EMUs [the spacesuits], including design inadequacies, health risks, and low inventories of spacesuit life support systems, ultimately leading to NASA’s efforts to design and develop next-generation suits to replace the existing EMUs. Specifically, the EMU design flaws have increased the chance of and led to unexpected water in helmets, thermal regulation malfunctions, and astronaut injuries. Given that spacesuits are necessary to meet future ISS maintenance needs until its planned decommissioning in 2030, it is critical that NASA effectively manages the contract performance and subsequent safety risks associated with ESOC [the contract with Collins].

…Until the ISS’s planned decommission at the end of the decade, NASA will continue to require spacewalking capabilities to perform upgrades and corrective and preventative maintenance to the Station. However, Collins’ performance on ESOC increases programmatic risks to NASA as it attempts to conduct safe spacewalks outside the ISS and maintain critical EMU life support component inventories. The contractor is experiencing considerable schedule delays, cost overruns, and quality issues that significantly increase the risk to maintaining NASA’s spacewalking capability.

Collins was awarded this five-year cost-plus maintenance contract in 2010 for $324 million. Since then NASA has been repeatedly extending it, so that it now runs through 2027 and has funneled $1.4 billion into Collins’ bank account. Yet Collins has repeatedly failed to deliver necessary repair parts, even as there have been more frequent problems on ISS, including several cases where spacewalks had to be aborted because an astronaut’s life was in danger. Here are just a few examples cited in the report:
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Collins officially backs out of contracts to build spacesuits for NASA

10:20 am

According to an announcement today from NASA, Collins Aerospace has now officially backed out of its NASA contracts to build a new spacesuit for both space station and lunar operations in the agency’s Artemis program.

In 2022 and 2023, NASA awarded Collins Aerospace two task orders under the agency’s xEVAS (Exploration Extravehicular Activity Services) contract. The first task order was to deliver a next generation spacesuit and spacewalking system for potential use on the International Space Station with a base value of $97.2 million. The second task order was to advance additional spacesuit capabilities with a base value of $5 million.

After a thorough evaluation, NASA and Collins Aerospace have mutually agreed to descope the existing task orders on the Collins Exploration Extravehicular Activity Services contract. This descope includes ending the International Space Station suit demonstration, which was targeted for 2026. No further work will be performed on the task orders. This action was agreed upon after Collins recognized its development timeline would not support the space station’s schedule and NASA’s mission objectives.

NASA still has a second and similar spacesuit deal with Axiom, which appears to be moving forward as planned. Whether the agency will consider new offers from other companies to replace Collins is not known at this time. It is instead possible NASA will reserve this $102.2 million to use to help Axiom if it runs into problems.

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Collins reportedly in the process of canceling its NASA spacesuit contract

9:19 am

As if NASA didn’t have enough spacesuit problems, with a ISS spacewalk this week canceled because one of the NASA-built suits on the station began leaking water again, Collins Aerospace, one of the two companies that won contracts to build new spacesuits, is now in negotiations to end that contract.

But Collins’ role in the program has been bumpy and development has fallen behind schedule, and the company has been in talks with NASA officials on how to wind down its role in the program, the two people said. “After a thorough evaluation, Collins Aerospace and NASA mutually agreed to descope Exploration Extravehicular Activity Services (xEVAS) task orders,” a Collins spokeswoman said in a statement, referring to the spacesuit contract.

If this story is confirmed, it means at present only Axiom is building new spacesuits that can either be used on ISS or on future Artemis missions to the Moon and Gateway. Whether NASA will put out the Collins contract for bid again is unknown. In its original cargo capsule contracts early in the 2010s, one company failed to raise sufficient funds to build its capsule, so NASA cancelled it and awarded Orbital Sciences and its Antares rocket and Cygnus capsule the deal.

If the contract is put out for new bidding, SpaceX would be in a very strong position to win, as its own internally financed spacewalk spacesuits are about to get their first flight test on Jared Isaacman’s Polaris Dawn mission on the Resilience Dragon capsule later this summer.

The failure of Collins here is disturbing, and might be an indicator of an overall loss in American engineering capabilities. Once a challenge like this would have posed no problem for any American aerospace company. Now such tasks are increasingly difficult and unachievable.

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Collins Aerospace tests its new spacesuit on the Zero Gravity airplane

9:37 am

On January 30, 2024 Collins Aerospace, one of two companies that NASA has contracted to design and build new spacesuits for its future missions, successfully tested its new spacesuit on the Zero Gravity airplane, where it was able to have a person use the suit in short but weightless conditions.

Collins is designing its suit in collaboration with ILC Dover and Oceaneering. Former NASA astronauts, John “Danny” Olivas and Dan Burbank, each donned the suit and performed a series of test objectives while onboard a Zero Gravity plane that’s able to perform parabolic maneuvers to simulate microgravity for short bursts. They were surrounded by several support personnel who were gathering data about the suit performance.

In total, they performed 40 parabolas during the flight. Collins said the primary goals included “evaluation of the suit’s pressure garment system fit and functionality, use of International Space Station tools and interfaces, and reviewed performance of the new Extravehicular Mobility Unit, or EMU, against the current design.”

The two spacesuit contracts (the second is with Axiom) are costing NASA about $335 million total to get the suits designed, built, and certified for use in spacewalks and ground operations on the Moon. Both companies appear on schedule to deliver those suits in less than three years.

Previously, NASA had tried to build new spacesuits on its own, and had spent a billion dollars over fourteen years while building nothing. The contrast in this story between the government and private enterprise should be clarifying to everyone.

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NASA awards Collins contract to build spacesuits for space station spacewalks

9:22 am

Capitalism in space: NASA yesterday awarded Collins Aerospace a $97.2 million contract to build spacesuits for the agency’s future space station spacewalks.

In June NASA had picked Collins and Axiom as the vendors who would build spacesuits for the agency. In September it purchased its its first Artemis Moon spacesuits from Axiom. This new contract has NASA buying its first new space station suits from Collins.

In both cases, the companies own their designs, and can thus sell them to the other private space stations presently under construction.

This contract award follows NASA abandonment of its own failed spacesuit effort, which spent fourteen years and a billion dollars and produced nothing.

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