NASA’s IG: With only Axiom building NASA’s future spacesuits, the agency’s lunar program faces great scheduling risk

Axiom's two spacesuits being tested underwater
Axiom’s two spacesuits being tested underwater in October 2025.
Click for original.

According to NASA’s inspector general’s report today [pdf] on the state of NASA’s effort to create new spacesuits for use by its astronauts on future space stations as well as in its Artemis lunar program, the planned schedules for the lunar landing and those stations are threatened because the agency presently has only one contractor, Axiom, building new suits, and has not established any spacesuit standardization rules should it want to issue contracts to others. From the report’s conclusion:

While NASA is taking steps to mitigate schedule risk, it must also contend with the unique risks inherent to a single-provider environment until future competition is introduced. … If Axiom cannot satisfy its contractual requirements in a timely or cost-effective manner, then NASA could be forced to continue using the problematic EMUs throughout the life of the ISS and significantly adjust its lunar plans. [EMUs are the complex suits presently used on ISS, and would not work well for any lunar landing mission.]

While xEVAS [the new suit concept] is flexible enough to allow for additional providers, doing so may not help the Agency meet its more immediate Artemis goals. Critically, NASA must address existing design and safety risks resulting from the lack of standard requirements for spacesuits to be compatible with various lunar spacecraft and assets.

As shown by the photo above, the development of Axiom’s spacesuit has been proceeding, and seems likely to be available for next year’s Artemis-3 Earth orbit test mission. At the same time, it is still behind schedule, a fact that has been mitigated because NASA’s entire Artemis program is equally behind schedule.

The report lists three commercial companies that might be able to provide alternative suits, and thus some redundancy, as shown by the image below.
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ILC Dover to provide spacesuits and “softgoods” for Sierra Space’s LIFE space station

Sierra Space yesterday announced that it has signed a partnership deal with ILC Dover for it to provide spacesuits and other “softgoods” for Sierra Space’s LIFE space station, including helping to build the station’s inflatable modules.

ILC Dover will be an exclusive partner with Sierra Space for softgoods used to support inflatable space habitat systems for low-Earth orbit (LEO), lunar and Mars transport and surface habitation, and use cases even farther into deep space.

The two companies have already been working together on the development and testing of Sierra Space’s first prototype inflatable modules.

First look at the new Starliner flight suit being made by Dover

It appears that the flight suit that the company ILC Dover is making for Boeing’s Starliner manned capsule has been unveiled not by the company but as part of an exhibit at the Kennedy Space Centers’ visitor complex.

Boeing has also signed contracts with two companies to provide two different flight suits.

Announced late last month, Boeing’s choice of ILC Dover’s AES came somewhat out of the blue. The aerospace company had previously selected another spacesuit manufacturer, the David Clark Company, to provide pressure garments for astronauts launching and landing on its CST-100 Starliner capsules.

An example of the David Clark suit, which was first revealed in 2017, has already flown twice to space on Boeing’s two orbital flight tests. Although astronauts have yet to fly on the Starliner, an anthropometric test device (instrumented mannequin) named “Rosie the Rocketeer” was dressed in the suit for the trial missions.

Boeing’s next and, as currently planned, final Starliner test flight will carry a crew, who will also wear the David Clark suit, according to a statement released by the company. The ILC AES will be introduced once Boeing begins flying astronauts on NASA-contracted missions to and from the International Space Station in 2023.

“In the spirit of commercial human spaceflight, we made the decision to bring an additional Starliner spacesuit supplier online to introduce additional redundancy, flexibility and competition for crew accommodations on future flights to low-Earth orbit destinations. We expect to introduce the new suits during operational missions, and are pleased to see the market opening up and allowing more options for Boeing as well as our government and commercial customers,” read the company’s statement.

In my opinion, the graphics at the link of both suits show them both to appear more comfortable and better looking than SpaceX’s Dragon flight suits. That opinion however is just a question of taste and style, and has nothing to do with the suits’ operation or use.

Boeing picks company to manufacture flight suits for passengers on Starliner

Dover's spacesuits
ILC Dover’s spacesuits.

Capitalism in space: On May 26th ILC Dover announced it has been chosen by Boeing as one of two companies to manufacture flight suits for passengers on Starliner.

The Boeing AES [Ascent/Entry Suit] is based off ILC Dover’s commercial Launch, Entry, and Abort suit, SOL™. ILC Dover worked with Boeing to tailor SOL for the Starliner spacecraft to provide protection for astronauts during the most critical phases of spaceflight, including launch, docking, re-entry and landing. With over 50 years of spacesuit experience, the AES suit was designed to provide maximum mobility to operate, enter and exit the spacecraft, as well as provide protection for astronauts in case of an emergency.

The black spacesuit on the left in the picture is Dover’s SOL suit, which it is adapting for Boeing. The white suit is the spacewalk suit it has made for NASA for use on ISS, which I also think is the same spacesuit that has for now almost a decade had repeated problems with water leaking into the helmet.

In other words, big space Boeing has hired another big space company to build its Starliner flight suits. I hope ILC Dover does a better job with the AES suit then it has with its EVA suit.