Italy dresses the stars: a new Made in Italy spacesuit combines innovation, health and style

A smart spacesuit has been developed in Puglia, designed to help astronauts' bodies cope with one of the main challenges of space missions: the effects of microgravity. Sensors, electrodes, and technical fabrics work together to monitor muscle activity and reproduce some of the stimuli that the body normally receives on Earth.  

This technology was developed in Fasano (BR) and reached space in 2024 with Axiom Space's Ax-3 mission to the International Space Station. Aboard SpaceX's Crew Dragon, Italian astronaut Walter Villadei tested the suit in the configuration dedicated to muscle monitoring. Today, the project continues with a new version, EMSi_MK.02, which has undergone initial tests in parabolic flight. 

Exercising in Zero-G 

Floating weightless in space may seem like effortless movement, but for the body, it means losing an essential stimulus. In microgravity conditions, the body no longer has to constantly counteract its own weight, and the absence of mechanical load results in progressive physiological deconditioning. Even relatively short stays can have consequences for the musculoskeletal, cardiovascular, and neuro-vestibular systems, causing, among other things, muscle atrophy and bone demineralization. 

The suit was created to complement physical exercise with technology capable of stimulating the muscles in a targeted manner and amplifying the benefits of the astronauts' physical activities during missions. 

Suiting up with Earth's gravity 

The latest version of the suit, EMSi_MK.02, is designed to “read” movement through bidirectional biomechanical sensors and 12 integrated electromyography sensors. The collected data allows the system to adaptively regulate neuromuscular stimulation in real time through targeted impulses distributed over 48 electrostimulation points. 

The device, therefore, doesn't merely observe what happens to the body, but reacts to its movements: a principle that is also applied in other areas of Made in Italy robotics, where sensors and smart systems allow technologies to adapt their behavior in real time. With the suit, the goal is to increase the stimulus received by the muscles during exercise and partially recreate conditions experienced on Earth. 

Lightweight on the outside, high-tech on the inside 

Integrating this technology without hindering movement is another of the project's challenges. The entire system weighs less than 1.2 kilograms. The fabric is also part of the technology: the current configuration combines differential compression, antibacterial and thermoregulatory properties, and flame-retardant materials. 

The new configuration was tested during a series of parabolic flights in Ottawa, Canada, in collaboration with the International Institute for Astronautical Sciences, involving astronaut researchers Norah Patten and Shawna Pandya. The tests made it possible to verify the fit, components, and electromyographic data acquisition in microgravity. 

Space also has its own style 

In an environment where every movement counts, design and technology become inseparable. The suit must integrate electronics, sensors, and technical materials while maintaining comfort and freedom of movement. This approach pushes the boundaries of contemporary Italian design, bringing together aesthetics, performance, materials research and function. 

It is precisely this synthesis of form and innovation that led to EMSi receiving the ADI Compasso d'Oro in 2024. A project in which design and technological research go hand in hand: the original technology was developed with the support of the Department of Electrical and Information Engineering at the Polytechnic University of Bari, while the EMSi_MK.02 evolution was carried out under a contract with the Italian Space Agency (ASI).

When Made in Italy takes innovation into orbit 

From fashion to design, right up to the most advanced technologies: Italian expertise continues to find new fields in which to express itself. This spacesuit is an example of this, because it brings together scientific research, engineering and design in a solution that originated in Puglia and has made its way to the International Space Station. 

OpportunItaly showcases and promotes this wealth of expertise in international markets, creating new opportunities for Italian companies to connect with foreign operators. Join the program to discover the innovation and know-how of Italian aerospace. 

Sources
Esa-Bic
Asi
Rea Space

In summary

• Developed in Puglia, EMSi is a smart spacesuit that monitors and stimulates astronauts' muscles during space missions. 

• The EMSi_MK.02 version incorporates 12 electromyography sensors and 48 electrostimulation points to help counteract the effects of microgravity on the body. 

• Weighing less than 1.2 kg and awarded the ADI Compasso d'Oro in 2024, the project combines research, engineering and Made in Italy design.