Echo

Bone Conduction Headset with Hearing Protection for spacesuit

NASA's xEMU spacesuit features embedded speakers and a microphone, replacing the old communication cap but causing audio echo issues. Bone conduction headphones are being tested as a solution, while also addressing the need for hearing protection from suit noise. The challenge is to integrate bone conduction with over-ear protection for clear, comfortable long-duration EVA communication

NASA's xEMU spacesuit features embedded speakers and a microphone, replacing the old communication cap but causing audio echo issues. Bone conduction headphones are being tested as a solution, while also addressing the need for hearing protection from suit noise. The challenge is to integrate bone conduction with over-ear protection for clear, comfortable long-duration EVA communication

Role:

Design Engineer

Duration:

6 Months

Type:

Team of 3

Research
Research

We began with secondary research on bone conduction technology and headset ergonomics. After consulting mentors, we identified key pain points in existing products. Additionally, we analyzed current bone conduction headsets to deepen our understanding of their design and functionality.

We began with secondary research on bone conduction technology and headset ergonomics. After consulting mentors, we identified key pain points in existing products. Additionally, we analyzed current bone conduction headsets to deepen our understanding of their design and functionality.

Problem
Problem

After consulting with the NASA engineers, we have identified the pain points behind existing products, which also known as the “Snoopy Cap”.

• Invasive to the head

• No breathability

• Uncomfortable with the back strap

Objective

1. Reduce the noise level by 10dB

2. Clear audio

3. Durable & require minimal cleaning

4. Free mobility inside of the helmet

5. Secured on head/stability

6. Minimally invasive to the head

7. Fit 95% percentil user

First Round Ideation

Based on our previous research, we started the ideation process including sketches and low fadelity models, to design adjustable, lightweight, and ergonomic headset.

Prototypes were created through rounds of critiques and feedback. Eventually, three high-fidelity models were developed.

Concept-1 Wave
Concept-1 Wave

The Wave headset uses spring-connected bone conduction components for a secure, comfortable fit.

Adjustment knob for head band & angle. Torsion spring on Bone conduction 

Wave shaped cushion

Tightening knob on the back band Ribbed knitted back band (nylon)

Concept-2 Armor
Concept-2 Armor

Armor’s bone conduction ear cups enhance comfort and clarity without metal or air conduction.

Adjustable for all head sizes and shapes

Detachable Headband

Embedded Bone conduction

Layer of cooling gel (polyurethane foam)

Concept-3 Half Moon
Concept-3 Half Moon

Half Moon is a lightweight headset with ear molds that block sound while keeping the ear canal open.

Adjustable headbands (stainless steel)

Customizable ear mold

Strong contact bone conduction via shape memory metal

Evaluation

The three final concepts were compared and analyzed based on their pros and cons in terms of ergonomics, ventilation, adjustability, weight, and security

Final Concept

After consideration and feedback from the NASA Audio Engineering team, the decision was made to proceed with the “Armor” design, incorporating the unique backband feature from the “Wave” concept.

Interior Components

The design has been prototyped through multiple iterations, featuring different 3D-printed exteriors and the integration of bone conduction technology in the prototypes.

Soldering

Connecting BOA

Transducer

Exploration with 3D printing
Exploration with 3D printing
Audio Test

Conducted in a room with Minimum Noise.


1. The Tests are conducted in a room with minimum noise.

2. A speaker played background noise in different decibal level.

3. Random sentences with increasing complexities played in the headset.

4. Test subjects are to repeat the sentences played in the headset to their best ability.

Conducted in a room with Minimum Noise.

1. The Tests are conducted in a room with minimum noise.

2. A speaker played background noise in different decibal level.

3. Random sentences with increasing complexities played in the headset.

4. Test subjects are to repeat the sentences played in the headset to their best ability.

Comfort Test

  1. The headset ensures clear communication despite internal noise generated by the spacesuit.

  2. Over 90% of test subjects could recognize a sentence at 40 dB and 50 dB background noise level

  3. Over 75% of test subjects could recognize a sentence up to 60 dB background noise level

  1. The headset ensures clear communication despite internal noise generated by the spacesuit.

  2. Over 90% of test subjects could recognize a sentence at 40 dB and 50 dB background noise level

  3. Over 75% of test subjects could recognize a sentence up to 60 dB background noise level

Echo

Bone Conduction Headset with Hearing Protection for spacesuit

Exploded View
Exploded View
Outcome

Echo was one of two selected for further development and funding, with the goal of testing and refining the headset for testing by NASA. This prototype is currently being tested at NASA’s Johnson Space Center.

Special Thanks to my amazing teammates: Brianna Blue & Chanbin Im

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