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This paper documents the progress of a conceptual packaging design effort for a Portable Life Support Subsystem (PLSS). The concept discussed is a flexible backpack intended for use on the Constellation Program (CxP) lunar suit, also known as the Constellation Space Suit Element (CSSE). The goal of this effort is to reduce the weight of the PLSS packaging while also meeting CxP goals to develop systems that are less costly, more adaptable to mission and technology changes, and have more performance capability than that of existing systems or previous lunar systems. This flexible backpack concept relies on a foam protection system to absorb, distribute, and dissipate the energy from falls on the lunar surface. The testing and analysis of the foam protection system concept that took place during this effort indicate that this method of system packaging is a viable solution.

This paper discusses the Portable Life Support Subsystem (PLSS) packaging design work done by the NASA and Hamilton Sundstrand in support of the 3 future space missions; Lunar, Mars and zero-g. The goal is to seek ways to reduce the weight of PLSS packaging, and at the same time, develop a packaging scheme that would make PLSS technology changes less costly than the current packaging methods. This study builds on the results of NASA's in-house 1998 study, which resulted in the “Flex PLSS” concept. For this study the present EMU schematic (low earth orbit) was used so that the work team could concentrate on the packaging. The Flex PLSS packaging is required to: protect, connect, and hold the PLSS and its components together internally and externally while providing access to PLSS components internally for maintenance and for technology change without extensive redesign impact. The goal of this study was two fold: 1.