Design & Manufacturing of a Subscale Inflatable Module (IMOD) for Manned Space Applications
Nebiolo, M¹; Langlois, S²; Pirolli, M³; Monteleone, P³; Taubmann Montes, G^4
1Thales Alenia Space - Italia; ²ESA ESTEC; ³Aero Sekur; ⁴Sener

After the successful completion of the activities related to the Phase I in which all the critical technologies have been developed and tested at samples level, Thales Alenia Space Italia (TAS-I) has also completed the Phase II activities on the Inflatable Module (IMOD) program, with the outstanding teaming support of its subcontractors.

The work of this Phase II has been focused on the design, manufacturing and testing of a highly representative subscale breadboard structure for an inflatable manned module applicable to both orbiting and surface habitat in next future space exploration missions.

The main IMOD breadboard sizes are given by a diameter of 3.3 m and a height of 2 m. The module shape is derived from the baseline selected in previous system level studies (e.g. IHAB) performed by TAS-I for ESA. The presence of a lateral window is another peculiar aspect of the IMOD breadboard configuration.

The design and manufacturing main features are intended to be described in this paper to justify the finally achieved IMOD breadboard configuration:

The design aspects span from the inflatable parts (bladder and restraint) configuration up to their critical interfacing with the bulkheads and the lateral window frame.

The manufacturing technologies and processes are described for both the bladder and the structural restraint realization with particular reference to sealing aspects and high performance stitching methods.

The IMOD construction has been started in September 07 and results in the first European breadboard for a space manned inflatable structure.