ILC Dover, Inc.1994

Space Suit EvolutionFrom Custom Tailored To Off-The-Rack

Apollo Space Suits Were Custom Tailored

The Apollo space suit was basically a one-piece suit. Each suit was made to fit (custom tailored) each astronaut.Each Apollo mission required fifteen (15) suits to support the mission. The main, or prime, three-man crew eachhad three suits: I for flight; 1 for training; and 1 as a flight back-up in case something happened to their flightsuit, thus a total of 9 suits for the prime crew. The back-up three-man crew each had two suits: I for flight and Ifor training. The astronaut corps at that time included between 25 and 27 astronauts.

Shuttle Space Suits Are "Off-The-Rack"

The Shuttle astronaut corps includes about 120 men and women. The Shuttle space suit, to accommodate thelarge number of astronauts with widely varying body sizes, was designed to be made up of many interchangeableparts. These parts (upper and lower torso's, arms, etc.) are fabricated at ILC in different sizes, inspected/tested,then shipped to Johnson Space Center (JSC) where they are inventoried for the astronaut corps.

ILC Dover has a staff of about 15 people who work on-site at JSC. This staff is primarily responsible for thecontrol, use, and maintenance of the suit components produced in Frederica after they arrive at JSC. The staffalso develops and executes the crew training schedules. This involves everything from taking measurements andconducting fitchecks to de-stow and post-flight inspection/test of the space suit.

Measuring Up For Shuttle

At JSC, the body measurements of each Shuttle astronaut are taken and recorded, then the measurements areplotted against the size ranges available for each space suit component. The suit components are then assembledand the astronaut is "fitchecked." Once the astronaut is satisfied with the fit, then a training suit is assembledusing duplicate sized components. The astronaut will use this assembly for many mining events. A flight suit isthen assembled using the same size components and the astronaut will "checkout" this suit during chambertesting and other test events.

Training suits are usually assembled nine months prior to flight and flight suits are usually assembled four monthsprior to flight.

Pack Your Bags!

Just before a Shuttle mission, the suits designated for flight are tested, cleaned, and packed at JSC. Then they areflown to Kennedy Space Center (KSC) and stowed on the orbiter. After each flight the suits are returned to JSCfor post-flight processing and reuse.

ILC Dover, Inc.1994

ILC Dover, Inc.1994

Questions & Answers About Space Suits

1. I would like to know if you are making old stuff into new stuff?

No. Materials used in making the space suits are purchased from other manufacturers and we beginbuilding from scratch. The Apollo suits that were on the moon were designed for a special purpose andwere tailored for each astronaut. The new suits used on the Shuttle are not tailored and are designed forspecial features that were not required for the Apollo suit.

2. When did you start making astronaut suits?

ILC started designing suits in 1961; started making test and prototype suits in 1964; and starteddelivering suits for use by the Apollo astronauts in 1966.

3. How thick is the space suit?

Approximately 3/16" thick, 11 layers of materials.

4. Do you have astronaut suits there? How many do you have? How many sizes do you make? Doyou make space suits by the dozen, one at a time, or what?

ILC no longer builds custom-made suits for each astronaut. We now build separable components (arms,legs, boots, etc.) that attach together which provides many sizes. After a suit has completed its mission, itis disassembled. Some of its parts are then mated with other parts to build another suit of a different size.Once these component parts have been made, they are shipped to NASA's Johnson Space Center nearHouston, Texas. We do have a certification suit here, which is manned (worn) at ILC during a spacewalk. The number of components made depends upon the number of flights scheduled at a given time andthe number of people that would wear a particular size.

5. How do you make astronaut suits and what material do you use?

The suits are basically made by sewing and cementing various materials together, and then attachingmetal parts that let you join the different components together. Suit materials include: ortho-fabric,aluminized mylar, neoprene-coated nylon, dacron, urethane-coated nylon, tricot, nylon/spandex, stainlesssteel, and high strength composite materials.

6. How much does it cost to make a space suit?

It is difficult to express the cost of the suit; not all parts are made by ILC, It has been reported in thenews media that the spare suit costs two million dollars. This does not mean that each time the suit isused it costs two million dollars. If you would never use the parts for another astronaut or anothermission, then you would have a one-time use and the cost could probably be as high as what the newsmedia says it is.

ILC Dover, Inc.1994

7. How long does it take to make a space suit?

If all the parts and materials were available for use by one person. who possessed all the different skillsrequired, it would take that person almost 2-1/2 years to produce a space suit (roughly about 5,000man-hours of work). With the complement of personnel and various skills at ILC Dover, a suit can beproduced in three months.

8. What color do they have to be?

The reason that the suits are white is because white reflects heat in space the same as it does here onearth. Temperatures in direct sunlight in space can be over 275 degrees Fahrenheit.

9. When the astronauts go into space once and then when they go again, do they wear the samespace suits?

The astronauts will wear the same size component parts as the first mission unless body dimensions havechanged (for example, gained weight).

10. How many space suits have you made?

ILC has manufactured enough separable components to assemble 51 individual Shuttle space suits. Someof these suits are used for the astronauts' training here on earth. These training suits are not intended forflight.

11. Have you made any changes in the suits?

Since ILC started developing prototype space suits in 1964, there have been many, many changes basedon the usage of the suit. The Apollo suit, for example, was designed for only one mission and it had to belightweight to allow the astronauts to do work on the moon. The Shuttle suit, however, is designed onlyto work in zero gravity where the astronaut does not feel the weight of the suit, and it is designed to lastfor up to 15 years on many missions.

For these reasons, the Shuttle suit is much heavier than the Apollo suit was. The Apollo suit, including thelife support backpack, weighed about 180 pounds. The Shuttle suit, including the life support system,weighs about 310 pounds. The suit itself weighs about 110 pounds. If an astronaut weighing 175 poundswears the complete suit, the total weight is then about 485 pounds (310 + 175 =495).

Changes to the design of the space suit are constantly happening as we learn more about living andworking in space.

ILC Dover, Inc.1994

12. Is the suit too heavy for training on earth?

When training on earth, the astronauts use special lightweight parts and they do a lot of training in water(a large pool called a Weightless Environment Test Facility). When the suit is pressurized with breathingair and the astronaut goes into the water, it is something like being in a balloon and floating on the water.Weights are added around the waist so the astronaut will sink and stay under water. This gives the samefeeling of weightlessness the astronaut would feel in space.

13. How did you find out what cloth to use for the suits?

a) By engineers establishing design limits (how much heat and cold the hostile environment of spacepresents).

b) Again, by engineers calculating how well various materials will withstand the above established designlimits.

c) By engineers calculating how long the materials will last when the materials are sewn/cementedtogether, folded and creased, and moved to different positions by bending or rotating the shoulder,elbow, wrist, waist, hip, knee, and ankle.

d) By many hours of testing material samples.

14. Do you have to make changes in the suits for women astronauts?

There is no difference in a male or female suit, though the female usually requires a smaller size.

15. How many years has your business been open?

Since 1947.

16. How many people do you have working for you?

We have approximately 400 employees in Frederica, Delaware and 15 employees that work at theJohnson Space Center near Houston, Texas. About 60 of the Frederica employees am involved in thespace suit program.

17. Who was the first space suit for?

The first suit worn in spare was made for astronaut Alan Shepard when he flew on May 5, 1961 duringProject Mercury. This suit was not made by RZ. The first suit worn on the moon was made by ILC forApollo astronaut Neil Armstrong's July 20, 1969 moonwalk. The first EVA using suits for the SpaceShuttle was performed by astronauts Story Musgrave and Donald Peterson on April 7. 1983.

ILC Dover, Inc.1994

18. How much air does the space suit hold?

The amount of air in the suit will vary, depending upon the size of the suit. The extra large Shuttle suit,without anybody in it, holds 5.42 cubic feet of air; the extra small size holds 4.35 cubic feet. With anastronaut in the suit, the amount of free space remaining in the suit is 2 cubic feet.

19. How long does 2 space walk- (EVA) last?

During an Extravehicular Activity, or EVA (sometimes called a space walk), the astronaut has about 7hours, plus or minus a half-hour, to complete his or her work. This time is dependent on the rate theastronaut is using the available air and water from the backpack. The harder the astronaut works thefaster the air and water are used. The backpack also has a 30-minute emergency air supply that can beused to safely get the astronaut back inside the orbiter.

20. Is ILC responsible for the entire Shuttle space suit?

No. Actually Hamilton Standard of Windsor Locks, Connecticut is NASA's "prime contractor. " They areresponsible for the Extravehicular Mobility Unit, or EMU (the entire space suit). Hamilton Standardprovides the Portable Life Support System, the Display and Control Module, and several othercomponents. As a subcontractor to Hamilton Standard, ILC furnishes the Space Suit Assembly whichincludes a Liquid Cooling and Ventilation Garment, Boots, Lower Torso, Arms, Gloves, and the ThermalMicrometeoroid Garment (TMG) that covers the entire EMU.

21. What do you think you will make in the year 2000?

We at ILC hope to still be making space suits for Space Shuttle and Space Station astronauts. We alsohope to be designing and developing new suits for future astronauts going to the moon, Mars, andbeyond!

THE NEW APOLLO AND SKYLABSPACE SUITS

ILC Industries, Inc., through itsDover/Frederica Division in Delaware, Is theprime NASA contractor for design,development, and manufacture of space suitsfor the Apollo and Skylab Programs. Thesesuits afford the necessary safety, comfort andmobility to the astronauts during Apollo andSkylab missions.

Space suit development is a tribute toAmerican Industry. For Instance, Du Pont, theworld's largest chemical corporation,developed materials used in 20 of the 21layers In the ILC Industries space suit. None ofthese materials were developed with the moonin mind. Some were new materials, like"Kapton" film. Others, such as nylon, werediscovered more than thirty years ago byscientists who had no Idea of the distance theresults of their research would travel someday. Achievements In science are often put touse in unexpected places. In the case of thespace suit, materials which were developed foruse on earth ultimately found a place on themoon.

The space suit is an air-tight anthropomorphicstructure called the Pressure GarmentAssembly or PGA. In the space suit, theastronaut is protected from the extreme rangeof temperatures, the near vacuum of spaceand the micrometeoroid flux density that mightbe encountered in space or on the moon'ssurface. Without this protection, a man couldnot live, and would die within seconds afterbeing exposed to such hostile environments.

There are two basic configurations of the suitused to support Apollo Missions: an In-travehicular (IV) configuration designated asthe CMP A7LB PGA, and an Extravehicular(EV) configuration identified as the EV A7LBPGA. The CMP A7LB pressure garment con-figuration is worn by the Command Module

Pilot. The EV A&B configuration is worn by theCrew Commander and the Lunar Module Pilot.A slightly modified version of the EV A7LBPGA is planned for use during Skylabmissions.

The complete Extravehicular Mobility Unitsused for Apollo and Skylab missions areshown on the front cover. The ExtravehicularMobility Unit or EMU configured for Skylabmissions, shown in the foreground, is the mostcurrent space suit configuration for use inspace programs.

The pressure garment assembly interfaceswith the spacecraft environmental controlsystem, or the Apollo Portable Life SupportSystem (PLSS) or the Skylab Astronaut LifeSupport Assembly (ALSA). The pressuregarment is operational at differential pressuresof 3.70 to 3.90 pounds per square Inch; Intemperatures of -290 to +310 degreesFahrenheit for Apollo missions or -180 to +277degrees Fahrenheit for Skylab missions; andIn micrometeoroid flux densities normallyexpected within the lunar orbit perimeter aboutthe earth or a 300,000 mile orbit. The pressuregarment permits low torque body movementsfor operating spacecraft controls and speciallydesigned devices required for spaceexploration or traversing the lunar surface.

When pressurized, the differential pressuresImpose stress or tension on the suit wall. The"soft" suit becomes very rigid or stiff, andalmost impossible to bend except in thoseareas where specially designed joints areprovided to accommodate normal body flexure.An example of this stiffness: inflate a largecylindrical balloon or the inner tube of a tire,the balloon or tube will become very stilt andalmost Impossible to twist or bend. Withoutthese specially developed joints for the spacesuit, It would be virtually impossible for theastronaut to do useful work on the moon'ssurface. These special joints are installed Intothe CMP A7LB suit at the knees, wrist,shoulders, elbows, ankles, and thighs. The EV

A7LB suit was further modified to includespecial joints at the neck and waist to allowbending movements in those areas. Thisadded suit flexibility permits the astronaut toconserve his energy, reduce fatigue and towork for longer periods on the lunar surface.Normal body movements in the suit cause thesuit joints to bend. The force required to flexthese joints is applied against the inner suitwall or gas retaining layer. To preclude directwear on the gas-retaining layer, the suit isfitted with an inner scuff layer of nylon fabric.

Entrance Into the suit is made through restraintand pressure- sealing zippers. The entranceopening used In the CMP A7LB assembly ex-tends down the center of the back, from theneck area to the front crotch area. The EVAMB suit employs entrance zippers that extendfrom the let t side of the waist, around the backto the right side of the waist, and diagonally upto the right chest area of the suit. Routing of

the zippers in the EV A7LB suit was changedfrom that employed in the CMP model toaccommodate the new neck and waist joints.The entrance zippers can be operated by thecrewman if required, but zipper actuation isnormally done with the assistance of a fellowcrewmember.

There are two protective envelopes employedin the space suit: an Inner pressurizableenvelope, and an outer thermal andmicrometeoroid protective envelope. The innerpressurizable envelope Is called the Torso andLimb Suit Assembly (TLSA); this assemblyInterfaces with a detachable helmet, and a pairof removable gloves. The outer envelope usedfor thermal and micrometeoroid protectionIncludes an Integrated ThermalMicrometeoroid Garment (ITMG), a LunarExtravehicular Visor Assembly (LEVA) orSkylab Extravehicular Visor Assembly (SEVA),

and a pair of lunar boots that are used forApollo Lunar missions only.

The torso and limb suit consists of an innercomfort liner, a rubber-coated nylon bladder,and an outer nylon restraint structure with theexception of the shoulder, elbow, wrist, thighand knee joints. These joints are single wall,integrated restraint and bladder, bellows-likestructures.

The Thermal Micrometeoroid Garment (ITMG)Is composed of an inner layer of rubber-coatednylon, alternate layers of aluminized materialseparated by a low-heat-conducting spacerfabric, and an outer layer of fire and abrasionresistant material. This thermal cross sectionemploys the same Insulation principle as the"Thermos" bottle when the suit is exposed tothe near vacuum of space.

The Lunar Extravehicular Visor Assembly(LEVA) or Skylab Extravehicular VisorAssembly (SEVA) includes a shell assemblythat fits over the helmet, and that clampsaround its base. Two visors, two side-eyeshades, and a center eyeshade aresupported by the shell. The outer sun visoremploys a gold coating that reflects solar heatand light from its surface. The inner protectivevisor is transparent, although it includes anInner coating that retains heat being emittedfrom the face. The protective visor is usedwithout the sun visor during operations inshadow areas where visibility through the darksun visor would not be adequate. The visorsand eyeshades are adjustable and can bemoved to positions selected by the crewmanfor his comfort and safety.

The Lunar Boots are slip-on assemblies thatinclude a cross section of materials similar tothose In the ITMG. There are additional layersof materials used in the boot sole as necessaryto reduce the transfer of heat from the lunarsurface to the foot. Metal-woven fabric or"Chromel-R" forms the outer shell of the bootsto resist high lunar surface temperatures and

surface abrasion. The outer structure of theboots in the sole consists of silicone rubberthat is sewn to the outer metal fabric shell andaffords Improved wear and thermal protectionto the boots.

For each PGA, there are two pairs of glovesused to support Apollo and Skylab missions:Intravehicular (IV) Gloves and Extravehicular(EV) Gloves. The IV Glove is a single-wallrestraint and bladder structure formed to fit thecrewman's hand. For scuff protection andadded structural support, an outer gauntlet andpalm restraint system is fitted over the glove.The palm restraint affords Improved handdexterity for operating spacecraft controls andspecial devices. The EV Glove Includes an IVGlove that Is fitted with an outer thermal glovethat employs a similar cross section to that ofthe ITMG. For abrasion and thermal protection,the outer shell is constructed of metal-wovenfabric, and the fingertips are fitted with siliconerubber caps. The outer thermal glove extendswell back over the IV glove-TLSA juncture.

Gaseous oxygen is circulated through the suitby the PLSS (backpack) or ALSA, or thespacecraft environmental control system forrespiration, pressurization, and ventilationpurposes. The oxygen is directed to the helmetfrom Inlet gas connectors on the suit, downover the body, to the arm and leg extremities,and then is directed through ducts to theexhaust gas connectors. The Impurities areremoved from the gas stream as it passesthrough the spacecraft environmental controlsystem or portable life support system, andthen is recirculated through the suit.

The ventilation system removes body heatfrom within the suit during lV operations, orwhen free space EV activities are performedremote from the spacecraft. During lunarsurface excursions the metabolic heatgenerated by the body exceeds the capabilityof the ventilation system, so a liquid coolingsystem Is employed which removes the majorportion of body heat from within the PGA;

thereby reducing fatigue as a result of bodydehydration through perspiration. The LiquidCooling Garment (LCG) consists of a networkof polyvinyl tubing that is supported byspandex fabric. The garment is worn next tothe skin and covers the entire body exclusiveof the head and hands. A liquid coolant orwater is circulated through the tubing from theportable life support system. In the suit, heat istransferred from the body to the liquid throughthe tubing wall, and in the portable life supportsystem, the heat is removed from the liquidbefore it is re-circulated back to the LCG.

Providing the spacesuit for the Apollo & SkylabPrograms is just one part that ILC plays in therole of protecting man from hazardousenvironments. ILC Industries, Inc. is proud ofits role in the space program and vigorouslysupports the ever-expanding field ofaerospace technology. We have over twentyyears of experience in research, development,and manufacture of air-inflated assemblies,pressure vessels and life support systems.This experience has provided a sound base forour continuing research, development anddesign of aerospace life support equipment,and has given ILC its place as the leader inthis field.

Although the Apollo and Skylab programsrepresent a tremendous challenge and a greatstep forward in aerospace technology, we atILC Industries see them as the beginningrather than the end of a long line of successfulefforts. We plan to utilize our experience andknowledge gained on these programs toadvance the state-of-the-art in other productsfor both government and Industry. Thecompany has already utilized materialsapplications developed for Apollo and Skylabequipment in other products, which are beingmanufactured. In this manner, the results oftechnology gained on space programs arepassed along to the consumer and the public.The walk on the moon is truly a step into thefuture.

0n July 20, 1969, as the world watched in awe when NeilArmstrong made his "One Small Step For A Man" ontothe lunar surface, a small engineering company locatedin Dover, Delaware was beaming with pride. Thatcompany was ILC Dover, and the pride felt at ILC wassurely justified; they designed and manufactured thespace suit astronaut Armstrong wore while makingAmerican history on the moon. That same pride wassustained throughout all fifteen Skylab and Apollo/SoyuzTest Project (ASTP) mission, during which ILC producedspace suits performed flawlessly. It is of little wonderthen, that in 1977 ILC Dover, as part of the HamiltonStandard team, was selected by NASA as Space SuitAssembly (SSA) contractor for the Space Shuttleprogram.

The MC Shuttle space suit is a pressure retentionstructure that, together with a life support systemprovides a life-sustaining environment, which protectsthe astronaut against the hazards of space. Suchhazards include a vacuum environment, temperatureextremes of -180 to +277 degrees Fahrenheit, and theimpact of micrometeoroids and orbital debris.

Unlike the space suits used in the Apollo or SkylabPrograms, where the entire suit was custommanufactured for a specific astronaut, the Shuttle suit iscomprised of separate components which can beassembled to make space suits to fit almost anyone(male & female). Several sizes of each component aremanufactured and placed on the shelf for future use.When needed, the components are selected from theshelf (depending on the astronaut's size) and assembledinto a complete space suit. The SSA and the LifeSupport System (LSS), when combined, become theExtravehicular Mobility Unit, or EMU. The EMU is usedfor all Shuttle program extravehicular space activities.

The SSA is designed and has been tested for aneight-year operational life. The design permits lowtorque body movements required for performance oftasks in space.

When pressurized, the "soft" material portion of the suitbecomes very rigid and nearly impossible to bendexcept where specially designed joints are provided.Such is the case when you inflate the inner tube of anautomobile fire.

The tube becomes very stiff and is difficult to twist orbend. Without these joints it would be virtuallyimpossible for the astronaut to do useful work. Thesespecial joints are located at the knees, wrists, shoulders,elbows, ankles, thighs and waist of the SSA. Normalbody movements by the astronaut cause the suit jointsto bend. This flexibility permits the astronaut toconserve energy, reduce fatigue and to work for longperiods of time.

A typical cross-section of the SSA is 11 layers deep,consisting of the liquid Cooling & Ventilation Garment(LCVG) (2 layers); pressure garment (2 layers); and theThermal Micrometeoroid Garment (TMG) (7 layers).Simply stated, the LCVG maintains astronaut comfort,the pressure garment provides containment of thebreathing air, and the TMG protects against themicrometeoroids which hit the suit, and insulates theastronaut from the extreme temperatures of space.

Communications Carrier Assembly (CCA)

The Communications Carrier is askull cap that interfaces with theElectrical Harness Assembly. Itcontains a microphone andearphones for voicecommunications. The skull cap ismade of teflon and nylon/lycrafabrics.

Hard Upper Torso Assembly(HIT)

The Hard Upper Torso is avest-like rigid fiberglassshell which incorporatesprovisions for Arm, LTA andHelmet attachment. A WaterLine and Vent TubeAssembly is fastened to theshell interior and interfaces

with he LCVG and the Life Support System (LSS). Themain portion of the LSS, containing water and oxygenstorage and circulation provisions, mounts on the backof the HUT, while the LSS controls mount on the frontwithin easy reach of the astronaut.

Arm Assembly

The Arm interfaces with theHUT by a ring that retains theArm Scye Bearing in the HUTopening. The upper and lowerarm joints are separated by anarm bearing, which allowslower arm rotation, the lower

arm also provides for sizing adjustments and for quickconnect/disconnect of the glove via a wrist disconnect.

Maximum Absorbency Garment (MAG) .

The Maximum AbsorbencyGarment is worn under the LCVGand provides for hygieniccollection, storage, and eventualtransfer of astronaut urine andfeces discharged duringextravehicular activities.

Helmet Assembly

The Helmet Assembly consists of atransparent Shell, Neck Ring, VentPad, Purge Valve, and anadjustable Valsalva device. TheHelmet is secured to the HUT andprovides an unobstructed field ofvision. Optical clarity of thetransparent shell is made possible

by the use of rugged, impact resistant polycarbonatematerial. A vent assembly, bonded to the inside rear ofthe polycarbonate shell, serves to diffuse the incominggas over the astronaut's face.

Lower Torso Assembly

The Lower TorsoAssembly consistsof an integratedBody Seal Closure,Waist, WaistBearing, Leg, Thigh,Knee and Anklejoints, plus Boots.The LTA enclosesthe lower body andinterfaces with theHUT via the bodyseal closure. Theflexible waist

section and waist bearing afford the astronaut a largedegree of movement about the waist, e.g. bending andhip rotation.

Glove Assembly

The Glove is made up ofa restraint and bladderencased in a TMG. Thegloves protect theastronaut's wrists andhands and are attachedto the arms at the wristdisconnects. The glovesincorporate a rotarybearing to allow wristrotation, a wrist joint toprovide flexion/extension,

fabric joints for thumbs and fingers, plus a hot pad forprotection of the hand from extreme hot and coldextravehicular conditions. The glove includes fingertipheaters that are controlled by the astronaut.

Extravebicular Visor Assembly (EVVA)

The Extravehicular VisorAssembly is alight-and-heat-attenuating shellwhich fits over the HelmetAssembly. It is designed toprovide protection againstmicrometeoroid activity andaccidental impact damage, plusprotect the crewmember from

solar radiation. A special coating gives the sun visoroptical characteristics similar to those of a two-waymirror; it reflects solar heat and light, yet permits theastronaut to see. Adjustable eyeshades may be pulleddown over the visor to provide further protection againstsunlight and glare.

Liquid Cooling & Ventilation Garment (LCVG)

The liquid Cooling &Ventilation Garment is aclose-fitting undergarmentcovering the body torso andlimbs. It incorporates anetwork of fine tubing that ismaintained in close contactwith the astronaut's skin byan outer layer of stretchableopen fabric. The space suitis so well insulated thatnormal body heat maintainswarmth, except foroccasional cold hands, evenon the cold, dark side of thespacecraft. However,cooling is required,therefore, water is circulatedthrough the LCVG tubing to

remove excess body heat. Water flows through thevarious inlet and return tubes and must be uninterruptedin order for the garment to be effective. The LCVG alsouses ventilation ducting to return vent flow from thebody extremities to the EMU Life Support System(LSS).

Insuit Drink Bag (IDB)

The IDB is a sealed bag thatcomes in two sizes, holding 21 oz.and 32 oz. of potable (drinking)water. The bag is secured byvelcro to the inside front of theHUT. Water is readily accessible tothe astronaut through amouthpiece located at the top of

the bag.

Since 1947, ILC has been active in the development ofproducts for both government and industry. Then astoday, most A C products are comprised of softgoodsmaterials - our primary area of expertise. Today, ILC'sproducts fall into six primary groups:

• Space Suits and Equipment

• Environmental Protection Products

• Individual and Collective Protection Equipment

• High Technology Inflatables

• Camouflage, Concealment, and Deception

• Human Engineered Composites

An astronaut working in the space shuffle orbiter cargo bay wears a spacesuit and a jet-powered, hand-controlled maneuvering unit. With thisprotection and equipment, the astronaut becomes an individual spacecraft able to move about and perform tasks in the microgravity of space.

WHY WEAR A SPACESUIT?

To explore and work in space, human beings must taketheir environment with them because there is noatmospheric pressure and no oxygen to sustain life.Inside the spacecraft, the atmosphere can be controlledso that special clothing isn't needed, but when outside,humans need the protection of a spacesuit.

Earth's atmosphere is 20 percent oxygen and 80percent nitrogen from sea level to about 75 miles up,where space begins. At 18,000 feet, the atmosphere ishalf as dense as it is on the ground, and at altitudesabove 40,000 feet, air is so thin and the amount ofoxygen so small that pressure oxygen masks no longerdo the job. Above the 63,000-foot threshold, humansmust wear spacesuits that supply oxygen for breathingand that maintain a pressure around the body to keepbody fluids in the liquid state. At this altitude the total airpressure is no longer sufficient to keep body fluids fromboiling.

Spacesuits for the space shuttle era arepressurized at 4.3 pounds per square inch (psi), butbecause the gas in the suit is 100 percent oxygeninstead of 20 percent, the person in a spacesuit actuallyhas more oxygen to breathe than is available at analtitude of 10,000 feet or even at sea level without thespacesuit. Before leaving the space shuttle to performtasks in space, an astronaut has to spend several hoursbreathing pure oxygen before proceeding into space.This procedure is necessary to remove nitrogendissolved in body fluids and thereby to prevent itsrelease as gas bubbles when pressure is reduced; acondition commonly called "the bends."

Spacesuits designed for the space station era willbe pressurized to 8.3 psi; therefore, the pre-breathingperiod will be shortened or diminished.

The spacesuit also shields the astronaut fromdeadly hazards. Besides providing protection frombombardment by micrometeoroids, the spacesuitinsulates the wearer from the temperature extremes ofspace. Without the Earth's atmosphere to filter thesunlight, the side of the suit facing the Sun may beheated to a temperature as high as 250 degreesFahrenheit; the other side, exposed to darkness of deepspace, may get as cold as -250 degrees Fahrenheit.

WARDROBE FOR THE SPACE SHUTTLE ERA

Astronauts of the space shuttle era have more than onewardrobe for space flight and what they wear dependson the job they are doing.

During ascent and entry, each crewmemberwears special equipment consisting of a partialpressuresuit, a parachute harness assembly, and a parachutepack. The suit, consisting of helmet, communicationassembly, torso, gloves and boots, providescounterpressure and anti-exposure functions in anemergency situation in which the crew must parachute

STS-26 crewmembers leave the Operations and Checkout Buildingat Kennedy Space Center, Florida, heading for the launch pad andlift-off. They are wearing partial pressure suits developed for thelaunch and entry phases of space flight.

from the orbiter, The suit has inflatable bladders that fillit with oxygen from the orbiter. These bladders inflateautomatically at reduced cabin pressure. They also canbe manually inflated during entry to prevent thecrewmember

Crewmembers of mission STS 61 -A perform experiments in thespacelab module in the space shuttle orbiter cargo bay. Astronautswork in a controlled environment of moderate temperatures andunpolluted air at sea-level atmosphere.

Space shuttle EMU components

from blacking out. Without the suit pressing on theabdomen and the legs, the blood would pool in the lowerpart of the body and cause a person to black out as thespacecraft returns from microgravity to Earth's gravity.The partial-pressure suit and equipment will support acrewmember for a 24-hour period in a liferaft in case ofan egress over water.

Working Inside the Space Shuttle

During orbit, astronauts work inside the space shuttle inshirtsleeve comfort. Prior to a mission, crewmembersare outfitted from a selection of clothing including flightsuits, trousers, lined zipper jackets, knit shirts, sleepshorts, soft slippers, and underwear. The materials ofevery component of the clothing are flame retardant.Covering the exterior of the garments are closablepockets for storing such items as pens, pencils, databooks, sunglasses, a multipurpose Swiss armypocketknife, and scissors.

Working Outside the Space Shuttle

To work in the open cargo bay of the space shuttle or inspace, astronauts wear the shuttle extravehicularmobility unit (EMU) spacesuit, which was developed tobe More durable and more flexible than previousspacesuits were. The suit is modular in design, withmany interchangeable parts. The upper torso, lowertorso, arms, and gloves are manufactured in differentsizes and can be assembled for each mission incombinations needed to fit men and women astronauts.This design is cost-effective because the suits arereusable and not custom fitted as were spacesuits usedin previous NASA manned space flight programs.

Suiting up

The EMU comprises the spacesuit assembly, theprimary life support system (PLSS), the display andcontrol module, and several other crew items designedfor spacewalks and emergency life support. The EMUaccommodates a variety of interchangeable systemsthat interconnect easily and

Astronaut Sherwood C. Spring wears the EMU while checkingjoints on a tower extending from the Space Shuttle Atlantis cargobay during mission STS 61 -B. He is standing on the end of the armof the remote manipulator system connected to the space shuttle.

securely in single-handed operation for either normal oremergency use. When preparing to work in space, theastronaut goes into the airlock of the space shuttleorbiter and puts on the following parts of the EMU:

• A urine-collection device that receives and storesurine for transfer later to the orbiter wastemanagement system.

• A liquid cooling and ventilation garment, aone-piece mesh suit made of spandex, zippered forfront entry, and weighing 6.5 pounds dry. Thegarment has water-cooling tubes running through itto keep the wearer comfortable during active workperiods.

• An in-suit drink bag containing 21 ounces of potablewater, the "Snoopy Cap," or communications carrierassembly, with headphones and microphones fortwo-way communications and caution-and-warningtones, and a biomedical instrumentation subsystem.

To put on the spacesuit, the astronaut first donsthe lower torso assembly and then rises into the topsection of the two-piece EMU spacesuit hanging on thewall of the airlock. The upper torso of the spacesuit is ahard-shell fiberglass structure that contains the primarylife support system and the display control module.Connections between the two parts must be aligned toenable circulation of water and gas into the liquidcooling ventilation garment and return. Then, the glovesare added and last to be donned is the extravehicularvisor and helmet assembly, which provides protectionfrom micrometeoroids and from solar ultraviolet andinfrared radiation. Bearings in the shoulder, arm, wrist,and waist joints allow the crewmember freedom of

movement. Bending, leaning, and twisting motions ofthe torso can all be done with relative ease.

All fabric-to- hardware connections are made witheither mechanical joints or adhesive bonding. Materialsused in the construction of the suit are selected toprevent fungus or bacteria growth; however, the suitMust be cleaned and dried after flight use.

The entire suit assembly is rated with a minimum8-year life expectancy. The nominal operatingatmospheric pressure in the suit is 4.3 psid. The suitcomprises several layers including apolyurethane-coated nylon pressure bladder, a polyesterstructural restraint layer with folded and pleated joints(for mobility), and a woven Kevlar, Teflon, and Dacronanti-abrasion outer layer.

The maximum total weight of the largest sizespacesuit assembly, including the liquid cooling andventilation garment, urine collection device, helmet andvisor assembly, communications carrier assembly, insuitdrink bag, and biomedical instrumentation subsystem, is107 pounds,

The astronaut is ready to go to work in space andsecures the necessary tools to the mini-workstation ofthe suit. The EMU lights are mounted on the helmet andare a necessity because during orbital operationsapproximately every other 45 minutes are spent indarkness.

Communications

An electrical harness inside the suit connects thecommunications carrier assembly and the biomedicalinstrumentation equipment to the hard upper torsowhere internal connections are routed to theextravehicular communicator by means of apassthrough.

The extravehicular communicator attaches to theupper portion of the life support system at the back ofthe hard upper torso, The controls are located on thedisplay and control module mounted on the chest at thefront of the upper torso. The extravehicularcommunicator provides radio communication betweenthe suited crewmember and the orbiter. In addition,electrocardiographic (EKG) information is telemeteredthrough the extravehicular communicator to the orbiterand to flight surgeons in the Mission Control Center atHouston, Texas.

The radios for spacewalk communications havetwo single UHF channel transmitters, threesinglechannel receivers, and a switching mechanism.These backpack radios have a "low profile" antenna - afootlong rectangular block fitted to the top of the PLSS.The radios weigh 8.7 pounds and are 12 inches long, 4.3inches high, and 3.5 inches wide.

Primary life support system

The PLSS consists of a backpack unit permanentlymounted to the hard upper torso of the suit and a

Astronaut Bruce McCandless 11 called the MMU "a great flyingmachine." McCandless was the first astronaut to use the MMU for aspacewalk on February 7,1984, during space shuffle mission STS41-8.

Control-and-display unit mounted on the suit chest. Thebackpack unit supplies oxygen for breathing, suitpressurization, and ventilation. The unit also cools andcirculates water used in the liquid cooling ventilationgarment, controls ventilation gas temperature, absorbscarbon dioxide, and removes odors from the suitatmosphere. The secondary oxygen pack attaches tothe bottom of the PLSS and supplies oxygen if theprimary oxygen fails. The control-and-display unit allowsthe crewmember to control and monitor the PLSS, thesecondary oxygen pack, and, when attached, themanned maneuvering unit.

Maneuvering in space

The manned maneuvering unit (MMU) is a one-man,nitrogen-propelled backpack that latches to the EMUspacesuit's PLSS. Using rotational and translationalhand controllers, the crewmember can fly with precisionin or around the orbiter cargo bay or to nearby freeflyingpayloads or structures, and can reach many otherwiseinaccessible areas outside the orbiter. Astronautswearing MMU's have deployed, serviced, repaired, andretrieved satellite payloads.

The MMU propellant - noncontaminating gaseousnitrogen stored under high pressure - can be rechargedfrom the orbiter, The reliability of the unit is guaranteedwith a dual parallel system rather than a backupredundant system. In the event of a failure in oneparallel system, the system would be shut down and theremaining system would be used to return the MMU tothe orbiter cargo bay. The MMU, which weighs

310 pounds, includes a 35-mm still photo camera that isoperated by the astronaut while working in space.

SPACESUITS FOR SPACE STATION AND BEYOND

When Edward White opened the Gemini IV hatch in1965 and became the first American to step into thevacuum of space, life-giving oxygen was fed to hisspacesuit by a 25-foot umbilical to a chest-mountedpressure regulator and ventilation assembly.

Exploring the Moon, however, required toreindependence from the spacecraft. The backpackportable life support system, a self-contained supply ofbreathing and pressurizing oxygen, filters for removingcarbon dioxide, and cooling water, gave Apollo crewmenthe independence they needed.

The PLSS supplied oxygen at 3.5 to 4 psi ofpressure while circulating cooling water through theliquid-cooling garment worn under the spacesuit. Lithiumhydroxide filters removed carbon dioxide from thecrewman's exhaled breath, and charcoal and Orlon

The Mark III suit is modeled at Johnson Space Center, where it isbeing evaluated for use in the space station era

filters sifted out odors and foreign particles from thebreathing oxygen. Metabolic heat was transferred fromthe cooling water loops to space through a waterevaporator system in the PLSS.

Mounted atop the PLSS was an emergency30-minute supply of oxygen and communicationsequipment for talking with fellow crewmen on the lunarsurface and with flight controllers in Mission ControlCenter in Houston. Additionally, the communicationssystems relayed back to Earth biomedical data on thecrewmen.

The Apollo lunar surface spacesuit and PLSSweighed 180 pounds on Earth, but only 30 pounds onthe Moon because of the difference in gravity.

With the advent of the space station program,work outside the spacecraft will be expanded to providenumerous unique on-orbit service capabilities not fullyachieved in previous space program operations.Currently, scientists and engineers at two NASAfacilities are working on a new generation of spacesuitsfor use during activity in space.

The Mark III suit, a combination of hard and softelements, is being developed at the NASA Lyndon BJohnson Space Center (JSC) in Houston, Texas. TheAX-5, a hard, all metal suit, is being developed by theNASA Ames Research Center (ARC) in California. Bothsuits share common design goals. For example, theymust be easy to get into and out of, must be comfortableto wear, and must allow adequate mobility and range ofmotion for the jobs to be performed. Both are designedto be altered to fit different size astronauts

The first seven astronauts selected by NASA in 1959 wear thespacesuits developed for Project Mercury.

For use on space station, the suit must also beeasily maintained and provide necessary protectionfrom radiation, micrometeoroids, and manmade debris.In addition to these requirements, both the JSC Mark IIIand the ARC AX-5 suit have been designed to operateat a pressure of 8.3 psi. Current space shuttlespacesuits operate at 4.3 psi and require atime-consuming pre-breathing operation prior to thebeginning of any spacewalk.

Pre-breathing allows the astronaut's body to adaptto the difference in pressure between the spacecraftcabin and the suit. By operating at a higher pressure,which more closely matches that of the space station,the new suit would greatly reduce or even eliminate theneed for pre-breathing. Astronauts in the space stationwill be able to prepare for outside activity in much lesstime.

HISTORY OF WARDROBES FOR SPACE

The Mercury spacesuit was a modified version of a U.S.Navy high altitude jet aircraft pressure suit. It consistedof an inner layer of Neoprene-coated nylon fabric and arestraint outer layer of aluminized nylon. Joint mobilityat the elbow and knees was provided by simple fabricbreak lines sewn into the suit; but even with these breaklines, it was difficult for a pilot to bend his arms or legsagainst the force of a pressurized suit. As an elbow orknee joint was bent, the suit joints folded in onthemselves reducing suit internal volume and increasingpressure.

Astronaut Edward H. White 11 was the first U.S. crewman to float inthe zero gravity of space. His spacewalk occurred during the flightof Gemini 4.

Apollo 17 scientist- astronaut Harrison H. Schmitt wears a protective spacesuit and helmet while collecting lunar samples at the Taurus-Littrowlanding site in 1972. His backpack is the portable life support system.

The Mercury suit was worn "soft" or unpressurizedand served only as a backup for possible spacecraftcabin pressure loss - an event that never happened.Limited pressurized mobility would have been a minorinconvenience in the small Mercury spacecraft cabin.

Spacesuit designers followed the U.S. Air Forceapproach toward greater suit mobility when they beganto develop the spacesuit for the two-man Geminispacecraft. Instead of the fabric-type joints used in theMercury suit, the Gemini spacesuit had a combination ofa pressure bladder and a link-net restraint layer thatmade the whole suit flexible when pressurized.

The gas-tight, man-shaped pressure bladder wasmade of Neoprene-coated nylon and covered byloadbearing link-net woven from Dacron and Tefloncords. The net layer, being slightly smaller than thepressure bladder, reduced the stiffness of the suit whenpressurized and served as a sort of structural shell,much like a tire contained the pressure load of theinnertube in the era before tubeless tires, Improved armand shoulder mobility resulted from the multilayerdesign of the Gemini suit.

Tailored for Apollo Moon Walking

Walking on the Moon's surface a quarter million milesaway from Earth presented a new set of problems tospacesuit designers. Not only did the Moon explorers'

spacesuits have to offer protection from jagged rocksand the searing heat of the lunar day, but the suits alsohad to be flexible enough to permit stooping andbending as Apollo crewmen gathered samples from theMoon, set up scientific data stations at each landing site,and used the lunar rover vehicle, an electric-powereddune buggy, for transportation over the surface of theMoon.

The additional hazard of micrometeoroids thatconstantly pelt the lunar surface from deep space wasmet with an outer protective layer on the Apollospacesuit. A backpack portable life support systemprovided oxygen for breathing, suit pressurization, andventilation for moonwalks lasting up to 7 hours,

Apollo spacesuit mobility was improved overearlier suits by use of bellows-like molded rubber jointsat the shoulders, elbows, hips and knees. Modificationsto the suit waist for Apollo 15 through 17 missions addedflexibility making it easier for crewmen to sit on the lunarrover vehicle.

From the skin out, the Apollo A7LB spacesuitbegan with an astronaut-worn liquid-cooling garment,similar to a pair of longjohns with a network ofspaghettilike tubing sewn onto the fabric. Cool water,circulating through the tubing, transferred metabolicheat from the Moon explorer's body to the backpack andthence to space.

Next came a comfort and donning improvementlayer of lightweight nylon, followed by a gas-tightpressure bladder of Neoprene-coated nylon or

bellows-like molded joints components, a nylon restraintlayer to prevent the bladder from ballooning, alightweight thermal superinsulation of alternating layersof thin Kapton and glass-fiber cloth, several layers ofMylar and spacer Material, and finally, protective outerlayers of Tefloncoated glass-fiber Beta cloth.

Apollo space helmets were formed fromhighstrength polycarbonate and were attached to thespacesuit by a pressure-sealing neckring. UnlikeMercury and Gemini helmets, which were closely fittedand moved with the crewman's head, the Apollo helmetwas fixed and the head was free to move within. Whilewalking on the Moon, Apollo crewmen wore an outervisor assembly over the polycarbonate helmet to shieldagainst eyedamaging ultraviolet radiation, and tomaintain head and face thermal comfort.

Completing the Moon explorer's ensemble werelunar gloves and boots, both designed for the rigors ofexploring, and the gloves for adjusting sensitiveinstruments.

The lunar surface gloves consisted of integralstructural restraint and pressure bladders, molded fromcasts of the crewmen's hands, and covered bymultilayered superinsulation for thermal and abrasionprotection. Thumb and fingertips were molded ofsilicone rubber to permit a degree of sensitivity and"feel." Pressure-sealing disconnects, similar to thehelmet-to-suit connection, attached the gloves to thespacesuit arms.

The lunar boot was actually an overshoe that theApollo lunar explorer slipped on over the integralpressure boot of the spacesuit. The outer layer of thelunar boot was made from metal-woven fabric, exceptfor the ribbed silicone rubber sole; the tongue area wasmade

from Teflon-coated glass-fiber cloth. The boot innerlayers were made from Teflon-coated glass-fiber clothfollowed by 25 alternating layers of Kapton film andglass-fiber cloth to form an efficient, lightweight thermalinsulation.

Wardrobe for Skylab and Apollo-Soyuz

Nine Skylab crewmen manned the Nation's first spacestation for a total of 171 days during 1973 and 1974.They wore simplified versions of the Apollo spacesuitwhile doing the historic repair of the Skylab andchanging film canisters in the solar observatorycameras. Jammed solar panels and the loss of amicrometeoroid shield during the launch of the Skylaborbital workshop necessitated several spacewalks forfreeing the solar panels and for erecting a substituteshield.

The spacesuit changes from Apollo to Skylabincluded a less expensive to manufacture andlightweight thermal micrometeoroid overgarment,elimination of the lunar boots, and a simplified and lessexpensive extravehicular visor assembly over thehelmet. The liquidcooling garment was retained fromApollo, but umbilicals and astronaut life supportassembly (ALSA) replaced backpacks for life supportduring spacewalks.

Apollo-type spacesuits were used again in July1975 when American astronauts and Soviet cosmonautsrendezvoused and docked in Earth orbit in the jointApollo-Soyuz Test Project (ASTP) flight. Because nospacewalks were planned, U.S. crewmen were equippedwith modified A7LB intravehicular Apollo spacesuitsfitted with a simple cover layer replacing the thermalmicrometeoroid layer.

Visitors to the Johnson Space Center in Houston, Texas, can see an exhibit of spacesuits.

Suit SizingNew space suitscan be sized inspace savingstorage, deliveriesBy Karen Schmidt

The STS-79 mission will carry into orbit a new spacewalking suit designed to fit more than one astronaut andsave storage space, bringing tomorrow's InternationalSpace Station technology into today's missions.

Extravehicular Activity space suits are the astronauts'lifeblood when they must work outside the protectedenvironment of a space shuttle. Equipped with lifesupport, an astronaut can spend up to seven hoursperforming maintenance tasks in the shuttle's cargo bayor on the future space station. With EVA tasks expectedto increase during station assembly and operation, JSC,in cooperation with Hamilton Standard, ILC Dover,Air-Lock and Boeing Aerospace Operations, isrevamping space suits to save storage space, meetweight limits and reduce the amount of equipmentrequired on flights to the station.

One of the first phases of the redesign was to developa way to resize a suit faster on the ground and in orbit.Currently, ground technicians change suit sizes bylacing in different lengths of fabric inserts.

"In order to make a suit fit an astronaut, techniciansmust change the inserts in the arms and legs of a suit,"said Ralph Anderson of the Flight Crew EquipmentManagement Office. "It is a long and cumbersomeprocess that takes about 16 hours to prepare a suit for aparticular astronaut."

Astronauts also are trained tochange-out inserts in the suits, butthe process is slow and tedious,taking up valuable on-orbit time.The new design features sizing ringsin both arms and legs that can bechanged out in less time.

"With the enhanced sizing rings, asuit technician can change the sizeof a suit in less than 20 minutes,"Anderson added.

Not only can suit technicians change the size of anEVA suit, the astronauts on orbit will have the samecapability.

"That's the whole idea, multiple crew members canuse the same suit for space walks on the InternationalSpace Station," Anderson said.

The new rings,made of aluminum,are available in 1/2size at the arm andthigh and threedifferent sizes for thelower leg-1/2, 1 and 11/2 inch. There alsoare four different sizesof leg segments andeight sizes of lower

arm segments that the astronauts can choose from. Oneleg attachment that fits from thigh to ankle can be sizedup to three inches-with so many combinations, a singlesuit can be sized to fit a number of astronauts.

"We will be able to carry a couple of suits and leavethem on the space station with enough sizingcomponents to fit different astronauts, therebyeliminating the need to carry suits for specific astronautson every flight," said Rodney Johnson, lead for theTraining Extravehicular Mobility Unit Laboratory atBoeing.

The design of the sizing ringsevolved from rings used on anadvance development suit. Themajor difference is that the newrings are threaded and twist on.Each ring has two automatic springlocks and one manual lock.

The new ring uses a pressure sealthat is an adaptation of the static

seal that we have been using for a decade and a half indisconnects found at the neck, gloves and waist," saidDon Lacey of ILC Dover. "Adapting proven designs

reduced our learning curve tremendously. The suit wasdesigned to meet the space station mission, but we willbegin to reap the benefits of this new suit right away."

In addition to the new rings,Adjustable Restraint Bracketsalso are being used for the jfirst time. They allowastronauts to lengthen orshorten the arm and legsegments in smallerincrements than the rings.

"You can lengthen eitherend up to one half inch," said-Scott Cupples of ILC Dover,11 giving an astronaut acustom fit."

The suits will fly for the firsttime on STS-79, but the bigtest will be on STS-82 whenthey will be used during scheduled space walks toservice the Hubble Space Telescope. Because theposition of the airlock on Discovery during STS-82effects its center of gravity, mission managers asked ifonly three suits could be flown for the four spacewalking astronauts.

Mission Operations STS82 EMU Lead Paul Boehmand back-up Dana Weigel were able to answer 'yes'because of the new sizing capabilities. MissionSpecialists Joe Tanner and Steve Smith will share onesuit, bringing enough sizing rings and leg attachments tocustom fit the two space walkers.

"We are relying on these rings to accomplish a resizein a much shorter time," Boehm said. "It is going to benice to have

the capability to do this on orbit, it gives us a lot moreflexibility and helps us focus on the primary objectivesof the mission."

"The sizing rings add a new, much needed capabilityto resize the EVA suits in flight," Tanner said. "Thiscapability allows us to carry only three suits toaccommodate four EVA crew members. The rings arevery easy to use, requiring only a few minutes to changearm and or leg segments to fit another crew member.The rings don't restrict your motion in the suit in anyway, in fact, I can't even tell they are there. Othermodifications that go along with the enhanced EMUallow crew members to make minor adjustments to armand leg segment lengths that could previously only bemade by a ground technician. The end result is a bettersuit with more capability and flexibility to carry us intothe station era."

More redesigns are in the works. The Hard UpperTorso, or HUT, will be fitted with new quick disconnectsinstead of bolt on attachments that connect the PrimaryLife Support System. These quick disconnects areexpected to work better and faster and the pivot pointsat the shoulders of the current HUT will be deleted togive the astronauts better mobility and make the suitmore robust. The new designed HUT also will removefour possible failure points that now exist in the oldermodel.

"If we had a space station today, this suit would beready to fly," said Tony Wagner, spacesuit subsystemmanager in the Crew and Thermal System EMU Group."We could leave it on the station for many space walksbefore it would have to return for maintenance. It iscertified and ready to go for EVA."

From top to bottom, left to right: 1) From left, Rodney Johnson, lead for the Training Extravehicular Mobility Unit Laboratory at Boeing Aerospace Operations,demonstrates how the new enhanced sizing rings work to NASA Deputy Administrator John Dailey and JSC Director George Abbey. 2) The new rings replacefabric sizing inserts that were hand laced into the suit by technicians, taking up to 16 hours to resize on suit. 3) Leg rings come in three different sizesassuring a custom fit for the astronauts. 4) Another new design feature is an Adjustable Restraint Bracket that gives astronauts a second length adjustmentfeature in the arms and legs of the space suit. 5) From left, Robert Nicholson and Ron Lindsey prepare a suit in the flight EMU laboratory for STS-79. 6)From left, Latonya Hagler and Nicholas Barnett check an arm ring assembly.

MILESTONES AND CAPSULEHISTORY

ILC Dover, Inc.

1947 International Latex Corp. dividesinto 4 separate divisions. One is anoutgrowth of the specialty groupnamed the Metals Division located atPear and Mary Streets in Dover,Delaware. The Metals Division makesdisplay racks for Playtex productssuch as girdles, swim caps, babypants as well as life vests, life rafts,and ant-exposure clothing. The otherthree divisions become Playtex(rubber and fabric goods), ChemicalDivision (now known as ReichholdChemical Co.) and thePharmaceutical Division (whichmakes items such as throatlozenges).

1952 Metals Division is awarded acontract to supply the Navy and AirForce with high altitude pressurehelmets. The work force at this time isabout 30 people.

1945 Stanley Warner Corp.purchases the controlling interest inthe International Latex Corp.

1955 Metals Division changes itsname to the Special ProductsDivision.

1956 The high altitude pressurehelmet contract is expanded toinclude high altitude pressure suits.The fact that the Special ProductsDivision was involved in rubbercompounding and dipping methodshelped resolve the problems of flexiblejoints in these suits (elbows, knees,and waists). Work continued on liferafts for the Army and prototypehelmets for the space program.

1958 Special Products Divisionbecame known as the IndustrialProducts Division.

1960 Production is busy with soft-goods assembly work which

includes ammunition pouches,harness straps and first aid pouches.

A facility in Frederica is used as awarehouse to support this production.

1962 The Industrial Products Divisionbegins work on the Apollo Space Suitas a subcontractor to HamiltonStandard. The work force at this timenumbers 50.

1964 The Industrial Products Divisionis re-named the Government andIndustrial Division.

1966 Government and IndustrialDivision is awarded prime contract onthe Apollo Lunar Space Suit. Ourwork force increases to 200.

1966/1967 International LatexCorporation formally splits into threeseparate entities: IPC (Playtex),Standard Brands (now Reichhold),and ILC Industries (formally theGovernment and Industrial division).In Nov. '66 ILC Industries, Inc. isincorporated in the State of Delawareas a wholly owned subsidiary ofStanley Warner Corp. On Dec. 221967 Stanley Warner Corp. is mergedinto the Glen Alden Corp.

In 1967, the company developed at itsown expense, a barrier bag used toprotect consumable-combustiblecartridge cases for munitions. Thecompany eventually sold 475,000barrier bags to the US Army.

Under an Air Force contract, ILCstarts the production of 384double-wall air supported structuresin the Frederica facility.

As a spin-off of the double-wallstructures, ILC starts designing,fabricating and installing single-wallair-supported structures used aswarehouses, field houses, and tenniscourt and swimming pool enclosures.

Drawing on experience gained on highaltitude helmet manufacturing in theearly 50's, ILC Industries, Inc. starts 8line of riot helmets and face-shieldsthat were used by police and firedepartments in larger cities during thelate 1960's. At this time ILC IndustriesInc. was manufacturing motorcyclehelmets along with the Vari-Shield faceshield which was popular withmotorcyclists and snow-mobilers alike.

1968 Our combined work force InDover and Frederica numbers 755.

At this time, 90% of the company'srevenues come from the space suitprogram.

We begin production of 1000inflatable boats for the US Army.

1969 In Jan. of 1969, ILC went publicand sold 225,000 shares of commonstock to the public at $7.25 a share.Glen Alden retained 70% ownership ofthe company. (All outstanding publicshares were purchased by RapidAmerican, when they acquired GlenAlden)

The proceeds of the sale were used topurchase Bio Medical Electronics Inc.,a producer of patient monitoringequipment that went out of business in1972.

July 20, 1969 will be remembered bymany ILC employees to be one of thehighlights of their lifetime. NellArmstrong, attired in an ILC IndustriesInc. designed and manufacturedApollo space suit took man's first stepon the moon. An interesting fact of thatmission and other lunar missions wasthat the space suit was the only item tobe used on the lunar surface andbrought back to earth, unlike theirother flight equipment. Our space suitswere used on the remainder of theApollo flights and in Skylab and theApollo Soyuz Test Project. It is worthmentioning that of the 15 missions our

engineering and technical support (techwriting, drafting, test lab, etc.).

1975 ILC Dover doses the Pear Streetfacility and consolidates the entireoperation in Frederica.

Total operations are performed in45,000 fl2 of building and 2 inflatablestructures. ILC rents the Fredericafacility for a sum of $22,000 a year.

Under a NASA contract ILC continuedspace suit development activities suchas Lightweight Intra-vehicular Suit, anImproved Thermal MicrometeoroidGarment, an EmergencyIntravehicular Suit and an OrbitalExtravehicular Suit.

ILC Dover wins a contract with theDefense Personnel support Center tomanufacture goggles for military use.These goggles have multiple lenses toprotect against sun, wind, and dust.ILC makes about 100,000 pairs ofgoggles a year for several years.

1976 ILC Dover wins a contract todevelop the DPE, a highly reliable,mobile, leak-free, disposableensemble for use in lethal chemicalenvironments. This is for the Army'sChemical Systems Laboratory inAberdeen, MD, now known asCBDCOM. This contract leads to ourChemturion suit line introduced in1979.

Today, Chemturions are being usedby the EPA, NIOSH, the Center forDisease Control in Atlanta, and manyindustrial companies such as DuPont,Dow, Georgia Pacific and Eli Lilly.

1977 ILC Dover is awarded thecontract to develop, certify andmanufacture the Shuttle Space Suit.ILC will subcontract to HamiltonStandard. We grow to 100employees.

ILC Dover develops a protectivegarment for use by the Environ-mental Protective Agency

Inspectors In hazardous environmentssuch as rail, truck and industrialchemical spills.

ILC Industries, Inc. is purchased byRapid American Corp. from GlenAlden Corp.

1978 ILC Dover further expands afterbeing awarded a NASA contract toprovide Crew Equipment and StowageProvisions for the Space Shuttle. ILCDover opens a new facility nearHouston's Johnson Space Center, andstarts a new division named ILCSpace Systems.

1980 ILC Dover is awarded a contractto design and fabricate theCyclocrane. The Cyclocrane is ahybrid aerostat with wings. Each winghas its own engine and propeller forlift and directional capability. TheCyclocrane is test flown In Oregon in1983.

1981 ILC Dover is awarded a contractto develop collapsible fuel and watertanks for the Army. Over a 9 yearperiod our designs of 3,000 gal.through 210,000 gal. (5,000 barrel)tanks are manufactured on an aroundthe dock work schedule. In this 9-yearperiod 5,280 tanks are manufactured.

We purchase the Frederica facility,which at that time consisted ofBuilding #1 plus 35 acres of land.Funds for this purchase are obtainedfrom the State of Delaware via anEconomic Development program thatprovides low interest rate loans toexpanding businesses within the state.

At peak employment times ourcompany population rises to 418.

ILC Dover is awarded a contractthrough NASA and the Air Force todesign and manufacture the PropellantHandlers Ensemble (PHE). The suitsare used to protect the handlers of

suits were flown on, they performedflawlessly.

1970 our work force has grown togoo. ILC Industries Inc. wins acontract to rebuild portions of theFamily 11 200,000 cubic foot balloonsin conjunction with the Air Force. Thisleads to the design and manufactureof a variety of Aerostats that are stillbeing manufactured today for use inthe United States' drug interdictionefforts.

In 1970 ILC Ind. Inc. purchasedSteinthal & Company Inc., anestablished manufacturer of militaryparachutes in Roxboro, N.C. Thecompany was eventually sold in 1976.

1971 ILC Industries Inc. expands withthe purchase of the Data DeviceCorporation located in Bohemia, NY.Data Device is engaged in theresearch and development,manufacture, and sale of advancedelectronic components.

The Dover operation becomes knownas ILC Dover, a Division of ILCIndustries, Inc.

ILC Dover manufactures and marketsa line of goggles used by skiers. Theyare known as 'ILC GOGGS".

1973 ILC Dover designs andmanufactures a liquid cooling vestthat is a spin-off of the coolinggarment used by, the astronauts. The'Cool Vest* m becomes an industrystandard and is still being marketedby ILC Dover, Inc.

1974 Skylab program ends and ILCDover experiences a major reductionin the work force. Over a 2-yearperiod the work force in Delaware isdown to only 25 people.

Manufacturing moves from Dover tothe Frederica facility followed by

XM40 Development contract is wonby ILC Dover to design and develop areplacement for the M17 Gas Mask.

1984 Kathy Sullivan is the first USWoman to walk in space, anothermilestone for ILC. She wears ourShuttle Suit.

ILC Dover becomes incorporated onJune 27, 1984. Its new name is ILCDover, Inc.

1986 Building 4 is erected adding33,000 more sq. ft. This becomes theBalloon production area. AlsoBuilding #5 (13,500 sq. ft) is built.

ILC Dover is awarded the contract todevelop an improved CollectiveProtective System (M28), betterknown internally as SCPE, for the USArmy.

1987 ILC Dover wins, a contract withBoeing to finalize design and qualifythe AERP Hood/Mask for Air Forceuse.

ILC Dover is awarded a contract fromthe Air Force to develop a newTransportable Collective ProtectiveSystem (TCPS) for use in chemicaland biological environments.

ILC begins work on the MK IIIadvanced development space suit.

Build #6 (12,000 sq. ft) is built.

1988 ILC Dover wins productioncontract for the Chemical BiologicalProtective mask (M40). We built at arate of 15,000 a month.

ILC is awarded a contract fromGeneral Electric for five 595K balloonsystems.

1989 ILC Dover under contract fromHoneywell begins production of Ram

liquid rocket fuel. 550 suits aremanufactured.

1982 Mr. Homer Reihm is namedPresident and General Manager ofILC Dover, Inc. At this same timeJohn McMullen and Carl Zlock arenamed Vice Presidents. Mr. Reihmwas our Vice President and GeneralManager from 1976.

Rapid American sells ILC Industriesto Mr. Leonard Lane. The Lane familystill owns the company today.

Building 2 is erected adding 38,000sq. ft. to our facilities.

ILC Dover is awarded the advanceddevelopment phase of the M43Hood/Mask integrated with a batterypowered motor blower filteringsystem, for use on the Apachehelicopter.

Torpedo recovery bags are developedand manufactured through a contractwith Rocket Research. Bags are usedto float Navy practice torpedoes forreuse. ILC receives multiple ordersfor additional bags over the years wecontinue to receive refurbishmentcontracts.

1983 ILC Dover again is in theforefront of the United States spaceprogram. Our Shuttle Suit is used onSTS-6 for EVA (the first flight of theChallenger) in conjunction with asatellite launch. This marks the firstAmerican to walk in space since1974.

ILC Dover under contract fromAerojet begins its first semi--automated assembly line, whichturns out 1,318,680 Air-inflatedDecelerator Systems (AIDS) through1988.

Building 3 is erected to addproduction floor space of 38,000 sq.ft. Our M40 mask production line isin this area now.

Air Decelerator (RAD) cup assemblies.Production runs for 1 year with1,843,000 units produced.

ILC (Antigua), LTD. becomes anoffshore soft-goods manufacturingfacility. RADs are manufactured therealong with the M40 Carriers and theHGU-41/P Hoods.

1990 ILC Dover is awarded aproduction contract for CollectiveProtection Systems (M28 and M200).

A Protective Integrated Hood Mask(PIHM) contract is awarded by Boeingto ILC Dover. 5,300 hood/masks areproduced.ILC Dover enters the world ofadvanced composites. We areawarded a contract from the GarretCorp. to develop spinner cones foruse on jet aircraft engines.

1991 ILC Dover is awarded a contractfrom the US Air Force to manufacture10,500 PIHMs.

ILC is awarded a contract by AlliantTechsystems to manufacture 100,000heat-sealed AIDS for use on NavyTomahawk missiles.

1992 ILC Dover is awarded a contractfrom Boeing to develop and fabricatethe Upper Pressure Garment, LowerG Garment, and Air Cooling Garmentof the F22 Aircraft Life SupportSystem.ILC Dover Is awarded a contract fromLoral for the detailed design andfabrication of 8 each 420,000 cubicfeet aerostats.

ILC Dover is awarded a contract forthe partial design and full fabricationof a 620,000 cu. ft. logging balloon.Due to Its success another balloon isawarded in 1993.

ILC Dover is awarded a contract fromthe Air Force for the first of three 275KAerostats.

1993 ILC Space System Division issold to Oceaneering Space Systems,Inc. of Houston, TX-

ILC installed its first Vapor GuardTank Cover at Relchhold ChemicalCorp. in Cheswold, Delaware.

1994 ILC Dover is awarded a contractby the German company Zeppelin forthe detailed design and fabrication ofa hybrid airship envelope.

ILC Dover is awarded a contract fromNASA's Jet Propulsion Lab (JPL) todevelop and manufacture the airbaglanding system for the MarsPathfinder Mission.

ILC produces our 500,000th M40 onDecember 9, 1994.

1995 ILC is awarded a contract todesign, develop and test an IntegratedBallistic Helmet (1131-1). This isfollowed by an order for 741production units.

ILC Dover teams with FPT IndustriesLtd. to be their US manufacturer offuel cells. The fuel cells are for theV22 Osprey aircraft manufactured byBoeing Helicopter, and are required towithstand gunfire and crash impactwith minimal damage.

1996 ILC wins a contract with satellitemanufacturer TRW to performpreliminary development of a SpaceRigidizable Antenna to enhancesatellite communications systemssuch as cell phones and Direct TV.

ILC again begins work to put peopleon the moon, performing a study forthe design of an Inflatable LunarHabitat.

In November of 1996, ILC is awardeda contract to build 184,000 M40masks.

ILC is awarded a contract to developthe Hasty Hide Shelter for the USSpecial forces. This camouflagesystem enablesthe

individual to conceal themselvesduring multiple day missions.

Dec. 4th 1996 - Mars PathfinderMission launches from CapeCanaveral with ILC's Alrbag LandingSystem aboard. The scheduledlanding date is July 4, 1997.