Texas Christian University Students Innovate Seam Design for NASA

In a groundbreaking achievement, four undergraduate students from Texas Christian University (TCU) have developed an innovative seam design aimed at preventing lunar dust from infiltrating astronauts' uniforms. This project, titled 'Optimized Suit Environmental Protection Garment Seams,' earned the team the 2025 Best Innovation Award at NASA's Johnson Space Center during the Spaceflight Human Optimization Conference held on April 29, 2025.

The team, consisting of fashion merchandising students Adelaide Lovett and Suzanna Tesfamicheal, along with biochemistry students Daisy Li and Amarige Yusufji, focused on creating a flexible seam structure that effectively mitigates the permeation of lunar dust. Traditional seams, such as flat-felled seams commonly found in jeans, were found to be less effective, as they could allow dust to collect on the outside of the garment. The students innovatively engineered a 'mutant' seam that folds inward, encasing the extra material within the garment, thus reducing the likelihood of dust accumulation.

Leslie Browning-Samoni, a TCU fashion merchandising professor who guided the students through their research and development process, emphasized the importance of this design. She stated, "The reason that we did that was when the extra material is on the outside, that can collect more dust," highlighting the potential implications for astronaut safety and equipment maintenance.

The team's efforts were supported by Felix Arwen, a softgoods engineering technologist at NASA, who provided mentorship throughout the project. Under Browning-Samoni's guidance, the students standardized seam construction parameters, including stitch length and needle type. They utilized high-performance fabrics such as Kevlar, Teflon, and polyurethane-coated textiles, sewn with either polyester or nylon threads, to enhance durability and functionality.

To test the efficacy of the seams in preventing dust penetration, the team employed lunar regolith simulant—a terrestrial material designed to mimic the properties of lunar dust. This material was subjected to rigorous testing in a rock tumbler, simulating the abrasive conditions of the lunar environment. The seams were sewn into pouches, which were weighed before and after the tumbling process to measure dust ingress. The results were analyzed under Keyence Microscopes, allowing the team to observe the micro-level impact of the dust on the seam materials.

Browning-Samoni explained the hazards associated with lunar dust, describing it as "hazardous, abrasive, and sticky." She noted that after spacewalks, astronauts need to ensure that no dust particles infiltrate their spacecraft to prevent damage to sensitive equipment. As NASA prepares for an expanded mission portfolio, including its Moon Surface Mission in collaboration with Axiom Space, the need for advanced protective gear is increasingly critical.

Whether the mutant seam will be integrated into future NASA spacesuits remains uncertain. A NASA spokesperson acknowledged inquiries about the seam's potential use but indicated that the appropriate Johnson Space Center contact would be unavailable for comment until the following week.

The TCU team's accomplishments also included delivering a formal pitch to NASA judges and presenting their work at the conference, which featured a scientific poster, seam samples, and microscope imagery of the dust-impacted materials. Their project culminated in a tour of NASA's Johnson Space Center, where they explored various facilities dedicated to astronaut training and innovation.

Browning-Samoni and her colleague Charles Freeman are also exploring the potential applications of the mutant seam in other areas, such as enhancing personal protective equipment (PPE) for agricultural workers exposed to chemicals. As members of NC170, a research group focused on improving PPE for environmental hazards, they aim to assess the versatility of their seam design across various fields.

The TCU students' innovative work exemplifies the intersection of fashion, science, and technology, paving the way for advancements in astronaut gear and beyond. The implications of their research extend into multiple domains, potentially revolutionizing protective clothing standards in various industries.