Next-Gen Kevlar Material to Undergo Testing on the ISS for Enhanced Space Debris Protection

A new material designed to protect against space debris is set to be tested aboard the ISS. This particular material, developed by DuPont and assessed by NASA at its New Mexico-based White Sands Test Facility, is a variant of Kevlar, a space-blanket polymer. 

This new version, dubbed Kevlar “EXO,” offers enhanced protection from space debris while being much lighter than traditional Kevlar. According to Jill Clements, DuPont’s global business development manager, the material passed NASA’s impact tests for orbital debris with reduced weight by as low as 40%.

During the White Sands Test Facility tests, researchers fired 0.4-inch wide aluminum bullets from specialized cannons at speeds of 4 miles per second toward 12 by 12-inch square targets. Even with reduced amounts of new protective material compared to standard space debris shields, the simulated debris fragments were unable to penetrate the test shields.

Testing Kevlar EXO in Space

DuPont is preparing to send samples of the Kevlar EXO material to the ISS to assess how it fares in the harsh conditions of space. Clements explained that the focus of these tests will be exposure to atomic oxygen and UV radiation, without evaluating its performance against debris, as that testing has already been completed on Earth. The samples, each measuring 2 inches on each side, will be sent in October to the ISS aboard a SpaceX Dragon cargo capsule, where they will be affixed to the station’s exterior for an extended period. 

DuPont launched Kevlar EXO in April 2023, hailing it as the “most significant” innovation in aramid fibers in over half a century. Aramids are durable, heat-resistant synthetic fibers, with Kevlar being one of the most well-known. Kevlar was first created in 1965 and has been widely used in bulletproof vests, combat helmets, and protective gear. In space applications, Kevlar has served as a thermal insulator for satellites and has been incorporated into debris protection systems since the 90’s. 

Clements explained that Kevlar EXO differs from traditional Kevlar, referring to it as a “cousin” of standard aramids. The enhanced strength of this new material allows for a significant reduction in the overall mass of space debris shields, which, she believes, will significantly benefit the space industry. 

Kevlar EXO’s Role in Future Space Exploration 

Clements emphasized that the industry recognizes the new material as revolutionary due to its substantial weight reduction for orbital debris protection systems. Launch costs are high, and companies are eager to minimize the mass used for shielding so that they can allocate more of their payload capacity for essential missions. She further noted that Kevlar EXO could benefit not only satellite manufacturers and spacecraft builders but also play a crucial role in protecting future inflatable space stations and structures on the moon and Mars.