Evolution of an Additive Manufactured Heat Exchanger for PLSS 2.5



Journal Title

Journal ISSN

Volume Title


48th International Conference on Environmental Systems


The next generation of extravehicular mobility unit (EMU) will require lightweight, high performance components in order to minimize the mass, volume and power of its portable life support system (PLSS). One component under development for this application is a gas / liquid heat exchanger that will cool the breathing gas delivered to the crewmember’s helmet. This technology has been gradually matured over the past several years. It started with a vacuum brazed compact heat exchanger used in NASA’s PLSS 2.0 and continued with two selective laser sintered heat exchangers, which were built using Inconel and titanium. This paper describes how the use of additive manufacturing has reduced weight, volume, cost, and manufacturing lead time of this line of heat exchangers. It also shows how performance test results have good agreement with the computational models.


Gregory Quinn, United Technologies Aerospace Systems
Jeremy Strange, United Technologies Aerospace Systems
Mark Zaffetti, United Technologies Aerospace Systems
ICES402: Extravehicular Activity: PLSS Systems
The 48th International Conference on Environmental Systems was held in Albuquerque, New Mexico, USA on 08 July 2018 through 12 July 2018.


Heat Exchanger, PLSS, Space Suit, Additive Manufacturing, Titanium