Electrospun Hydrogen-Rich Nanofibrous Mats for Lightweight Radiation-Shielding Concepts in EVA Suits

Hydrogen-rich polymeric materials are attractive candidates for lightweight passive shielding in crewed space systems, particularly where localized mitigation of particle radiation is desirable without significant mass penalties. Fiber-based solutions are especially appealing in this context, as they can combine shielding functionality with low density, flexibility, and favorable mechanical integration within multilayer non-woven structures. This work presents a sustainable approach to the fabrication of electrospun nanofibrous mats based on hydrogen-rich polymer systems for potential application in extra-vehicular activity (EVA) suits. Starting from water-based formulations, continuous nanoscale fibers were produced and assembled into porous mats characterized by low density, high specific surface area, and tunable composition, features of clear interest for multilayer non-woven structures. Morphology and structural uniformity were investigated by scanning electron microscopy (SEM), while Fourier-transform infrared spectroscopy (FTIR) and differential scanning calorimetry (DSC) were used to verify the coexistence of the polymeric phases and the successful incorporation of polyethylene within the fibrous structure. The resulting mats exhibited regular fibrous morphology together with clear spectroscopic and thermal evidence of composite formation, demonstrating that high loadings of hydrogen-rich phases can be integrated into electrospun systems through a scalable aqueous-based process. The absence of conventional toxic solvents further supports the relevance of the proposed route from a sustainability perspective. From an application standpoint, these materials are best suited for integration as inner or intermediate layers in EVA suit architectures, where their low mass, flexibility, and hydrogen-rich composition can be exploited for lightweight passive radiation shielding. Preliminary radiation transport simulations carried out using NASA’s OLTARIS indicated promising attenuation behavior, supporting further optimization as a function of areal density, layer thickness, and fibrous mat architecture. Overall, the results identify electrospinning as a versatile, scalable, and sustainable strategy for the fabrication of polyethylene-loaded polyvinyl alcohol fibrous systems, opening a viable path toward green, lightweight, and potentially multifunctional multilayer protection concepts for EVA suits and, more broadly, toward the localized shielding of sensitive electronics in crewed-space systems. This study was carried out within the framework of the Space It Up project, funded by the Italian Space Agency (ASI) and the Ministry of University and Research (MUR), which supports the development of innovative and sustainable materials for future space missions.