NASA Confirms Kevlar/PBI Webbing Meets Flammability Standards for Elevated Oxygen Habitats

The NASA Engineering and Safety Center has completed flammability testing on a commercial‑off‑the‑shelf webbing intended for use in the elevated‑oxygen habitats planned for future lunar and Martian missions. The webbing, a 60 % Kevlar® and 40 % polybenzimidazole (PBI) blend supplied by Sturges Manufacturing, passed NASA‑STD‑6001B Test 1 at 37 % oxygen and 8.2 psia in an unshielded J‑configuration. This result addresses a critical safety gap, because standard meta‑aramid or nylon webbings ignite under the same conditions. Off‑gassing measurements for the natural‑colored webbing also fell within acceptable limits. The findings open a path toward certified soft‑goods components for crew mobility aids and restraint systems.

What happened

NASA‑STD‑6001B Test 1 was conducted at White Sands Test Facility, using an unshielded J‑configuration where the igniter contacts the front surface of the material while the cut edge remains unexposed. The 60 % Kevlar/40 % PBI webbing sustained ignition without flame propagation, establishing a maximum oxygen concentration (MOC) of 37 % at 8.2 psia—exactly the target level for future crewed habitats. Off‑gassing data collected during the test showed volatile organic compound emissions well below the thresholds defined for crew cabin air quality.

These results contrast with baseline tests of conventional meta‑aramid and nylon webbings, which failed to meet the same flammability standard under identical conditions. The successful webbing is a commercial‑off‑the‑shelf (COTS) product, meaning it can be sourced without a bespoke manufacturing program, accelerating integration into upcoming mission hardware.

Why it matters

Elevated‑oxygen environments reduce prebreathe time before extravehicular activities, a key operational benefit for lunar and Martian surface missions. However, higher oxygen levels dramatically increase fire risk, making material certification essential for crew safety. By validating a COTS webbing that satisfies NASA’s fire‑resistance requirements, the agency removes a bottleneck in the development of soft‑goods such as restraint nets, mobility aids, and storage‑bag handles. This not only shortens hardware timelines but also provides a proven baseline for future material‑selection trade studies.

How to think about it

Designers should treat the Kevlar/PBI webbing as a qualified baseline material for any soft‑goods component that will reside in an environment of 37 % O₂ at 8.2 psia. Incorporate it into hazard analyses and fire‑mitigation plans, but still conduct subsystem‑level durability testing that reflects expected tension cycles, UV exposure, and abrasion. When evaluating alternatives, compare not only flammability but also off‑gassing profiles, tensile strength, and long‑term thermal stability. Document any deviations from the tested configuration (e.g., dyed colors or additional coatings) and plan supplemental testing before flight approval.

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