Defining the Space Suit of Tomorrow

Star Helix is a UK-based interdisciplinary research and development company specializing in adapting terrestrial technologies for space applications. With a strong network in the UK, USA, and beyond, the company focuses on life support systems, spacesuit components, radiation shielding, microbial control, and diagnostic wearables. Star Helix is developing innovative, space-ready technologies by adapting proven solutions from biotechnology, MedTech, engineering, and advanced materials. Collaborating with industry, academia, and the public sector, focusing on uncompromised reliability in the most demanding environments of the growing space economy. 

Star Helix partnered with TECHNIA to develop innovative 3D-printable wrist joints for next-generation EVA (extravehicular activity) and IVA (intravehicular activity) suits. Leveraging advanced design engineering and simulation technologies, the collaboration aimed to deliver groundbreaking solutions for use in both space exploration and hazardous environments on Earth.

“TECHNIA drew us in with the remarkable range of software capabilities, as well as their willingness to explore new approaches to problem solving. Working with them has been educational, and we’re impressed with the friendliness and expertise of their employees. We look forward to continuing our professional relationship.”  

Dr Natasha Nicholson, CEO | Star Helix

Overcoming outdated designs and building flexible, airtight spacesuit joints 

Star Helix faced critical challenges in revolutionizing space suit technology that had remained largely unchanged since the 1960s:

• Current EVA suits used outdated steel ring and ball bearing systems with restrictive mobility and chronic leakage issues (two liters of oxygen per hour). 
• Need to develop airtight, structurally strong, yet flexible and lightweight wrist joints using innovative origami folding techniques applied to 3D-printing materials. 
• Limited in-house design engineering capability to present novel concepts to funding bodies. 
• Tight deadline pressure for the ESA BIC (European Space Agency’s Business Incubation Centre) funding application submission. 
• Requirement for quantitative evidence to support innovative design concepts for both space and terrestrial applications. 

Advanced simulation and origami design breakthroughs

TECHNIA delivered comprehensive design engineering and simulation services using advanced Dassault Systèmes software:

• Rapid two-week development timeline using 3DEXPERIENCE platform. 
• Geometry modeling in SOLIDWORKS aligned with Star Helix’s existing software capabilities. 
• Advanced analysis setup using SIMULIA, leveraging the powerful Abaqus solver. 
• Quantitative comparison of three different origami-based designs against a baseline model. 
• Collaborative dashboard on the 3DEXPERIENCE platform for seamless information sharing. 
• Physics-based simulations, providing demonstrable evidence for funding applications. 
• Professional design engineering expertise drawn from multiple industry sectors.
• TECHNIA engineers led the modeling and simulation work, ensuring optimal balance between structural rigidity and wearer flexibility. 

Securing funding to accelerate spacesuit design innovation

The partnership delivered significant breakthroughs:

• Identified optimal origami pattern, achieving superior balance of rigidity versus flexibility. 
• Accelerated the development process by many months, enabling on-time funding submission. 
• Provided quantitative and visual simulation results as demonstrable evidence for ESA BIC application. 
• Created a significantly stronger funding bid backed by rigorous physics-based simulations. 
• Demonstrated technology transfer potential for terrestrial hazardous environment applications. 

Exploring the benefits of cross-sector collaboration

This truly collaborative project demonstrated TECHNIA’s ability to bring design and simulation expertise from multiple sectors, adding real value through fresh perspectives on spacesuit innovation. Star Helix’s real-world EVA suit experience combined with TECHNIA’s technical capabilities ensured an optimal funding bid with no missed opportunities.