NASA's Management and Development of Spacesuits: Critical Report of the Inspector General, Shortage of Extravehicular Mobility Units (EMUs) for Space Station, Development of Exploration and Mars Suits

NASA continues to manage an array of design and health risks associated with the EMUs used by ISS crew. In addition, only 11 of the 18 original EMU Primary Life Support System units - a backpack-like structure that performs a variety of functions required to keep an astronaut alive during a spacewalk - are still in use, raising concerns that the inventory may not be adequate to last through the planned retirement of the ISS. Given these issues, NASA will be challenged to continue to support ISS needs with the current fleet of EMUs through 2024, a challenge that will escalate significantly if Station operations are extended to 2028.
Despite spending nearly $200 million on NASA's next-generation spacesuit technologies, the Agency remains years away from having a flight-ready spacesuit capable of replacing the EMU or suitable for use on future exploration missions. As different missions require different designs, the lack of a formal plan and specific destinations for future missions has complicated spacesuit development. Moreover, the Agency has reduced the funding dedicated to spacesuit development in favor of other priorities such as an in-space habitat.
After examining these spacesuit development efforts, we question NASA's decision to continue funding a contract associated with the Constellation Program after cancellation of that Program and a recommendation made by Johnson Space Center officials in 2011 to cancel the contract. Rather than terminate the contract, NASA paid the contractor $80.8 million between 2011 and 2016 for spacesuit technology development, despite parallel development activities being conducted within NASA's Advanced Exploration Systems Division. Moreover, given the current development schedule, a significant risk exists that a next-generation spacesuit prototype will not be sufficiently mature in time to test it on the ISS prior to 2024. Finally, little schedule margin exists between anticipated delivery of the Orion Crew Survival System spacesuit in March 2021 and NASA's current internal launch date of August 2021 for its first crewed mission beyond low Earth orbit.