---
title: Metakosmos and UTS Apply Computational Design to Spacesuit Fit
description: The Metakosmos and UTS collaboration applies geometry processing and digital fabrication research to spacesuit form and fit optimisation.
---

 Sep 8, 2026 · 5 min read

# Metakosmos and UTS Apply Computational Design to Spacesuit Fit

 The Metakosmos and UTS collaboration applies geometry processing and digital fabrication research to spacesuit form and fit optimisation.

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 Metakosmos

 Metakosmos Editorial Team

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Metakosmos and the University of Technology Sydney are collaborating on digital optimisation of spacesuit form and fit. The work is funded under the New South Wales Space Research Network's Seed Project Program and draws on UTS research in geometry processing, mesh parametrisation and digital fabrication.

## THE ENGINEERING PROBLEM

A pressurised garment resists any motion that changes its enclosed volume. A joint holding constant volume through its range of motion requires little torque to move. A joint that does not requires the wearer to work against the suit for the duration of the mission.

Fit determines where those volume changes occur. A suit sized to a body geometry different from the wearer's places suit articulation out of alignment with the wearer's own joints. NASA research documents the result: contact injuries from impact with the suit and strain injuries from repeated high-force movement, with hand and finger injuries most frequent in both training and flight.

## MANUFACTURING CONSEQUENCE

Suit production has been substantially hand-executed, with bespoke sizing meaning little transfers between articles.

Parametric sizing generated computationally across a wide anthropometric range, paired with automated production, replaces individual fabrication. That work underpinned the Engineering Business of the Year award at AusSpace24 in July 2024, which recognised reducing manufacturing cost and customising suits for varying body shapes through digital optimisation.

## ACCOMMODATION RANGE

Spaceflight human performance data has been drawn from a narrow range of body types. NASA's Artemis surface suit is designed to fit a substantially wider range of astronauts than earlier generations.

The requirement is more demanding across the [four operating domains](https://www.metakosmos.co/domains), where workforces are more varied than astronaut corps.

## INTO HARDWARE

Computational design feeds the [CORE suit integration architecture](https://www.metakosmos.co/core). It also constrains [instrumentation](https://www.metakosmos.co/pulse), because sensor placement depends on body geometry and a sensor reading correctly in a static fit check can read incorrectly during articulation.

Mobility torque across the pressure range is measured on [SUITRIX rigs](https://www.metakosmos.co/prove/suitrix) using [SYNHUM](https://www.metakosmos.co/prove/synhum), which provides a body geometry that is exactly repeatable between runs.

### References

- [Metakosmos - CORE](https://www.metakosmos.co/core)
- [Metakosmos - LABS](https://www.metakosmos.co/labs)
- [Metakosmos - PROVE](https://www.metakosmos.co/prove)
- [Metakosmos - SUITRIX](https://www.metakosmos.co/prove/suitrix)
- [Metakosmos - SYNHUM](https://www.metakosmos.co/prove/synhum)
- [Metakosmos - PULSE](https://www.metakosmos.co/pulse)
- [Metakosmos - Domains](https://www.metakosmos.co/domains)
- [Metakosmos - Space](https://www.metakosmos.co/space)
- [Australian Manufacturing — Sydney startup Metakosmos, UTS pioneer next-gen spacesuit designs](https://www.australianmanufacturing.com.au/sydney-startup-metakosmos-uts-pioneer-next-gen-spacesuit-designs/)
- [Manufacturers' Monthly — Metakosmos wins big at AusSpace24](https://www.manmonthly.com.au/metakosmos-wins-big-at-ausspace24/)
- [NASA HRP — EVA injury evidence report](https://ntrs.nasa.gov/api/citations/20170002574/downloads/20170002574.pdf)
- [NASA — Spacesuit for Artemis III Moon Surface Mission Debuts](https://www.nasa.gov/humans-in-space/spacesuit-for-nasas-artemis-iii-moon-surface-mission-debuts/)

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