bone conduction headset

Wearable Technology Studio – Bone Conduction Headset

The wearable technology studio introduces students to a research-based design approach where teams work with interdisciplinary project mentors from non-design backgrounds ranging from aerospace and mechanical engineering to health and medical professionals. Students are introduced to soft materials, smart textiles, and other technological advances in sensors and microcontrollers.

This project: the development of a Bone Conduction Headset with Hearing Protection for xEMU by students Giulio Roversi and Efe Gulboy was developed with NASA in response to their Wearable Technologies Challenge Day challenge, hosted by the Technology Collaboration Center.

What we did

  • Literature review
  • Design research
  • Materials research
  • Design, prototyping and testing
  • Create a final working prototype
  • Present project to NASA

Clients / Collaborators

NASA xEMU bone conduction headset
Bone conduction headset

Project Overview

The new spacesuit being developed for exploration EVAs (Extravehicular Activities), called xEMU (Exploration Extravehicular Mobility Unit). Commercial bone conduction headphones were identified as a viable option to wear under the xEMU helmet, however there are challenges that come with bone conduction. The open speakers and microphones inside the helmet cause echo during communication, and the headsets require more power to achieve adequate loudness. Additionally, while bone conduction works well for low frequencies, it is less effective for higher frequencies, which impacts audio clarity. These issues needed to be addressed to ensure reliable communication and optimal audio performance during space missions.

The solution is a lightweight, highly comfortable modular headset that prioritizes noise isolation and secure fit using customized in-ear molds.

bone conduction headset illustrations
xEMU bone conduction headset prototypes
bone conduction headset prototypes
illustrations of bone conduction headset

Design Solution

The innovation of the solution is the custom in-ear molds, which are custom fit to each user to maximize comfort and a secure fit for extended wear. The other key feature of the headset is the modular design, which includes universal over-ear cups that provide noise isolation and an adjustable harness that can fit a wide range of head sizes.

Other features include elastic bands with cooling gel pads at pressure points, TPU components for durability and flexibility, and gel cushioning to keep the ears cool. Foam cushioning covered in spandex enhances comfort, while elastic bands with Velcro straps provide an adjustable fit, accommodating various head shapes and hairstyles. The custom-molded ear inserts, attached via magnets, ensure a personalized and secure fit. Extensive testing confirmed the headset’s comfort, stability, and reliability, even during prolonged wear and rigorous activities. The design successfully addresses the needs of users in demanding environments, offering a superior audio experience.

xEMU bone conduction headset
xEMU bone conduction headset

Outcome

Due to the innovation of the modular and customizable design and the success of the prototype, this project was one of two selected for further development and funding, with the goal of testing and refining the headset for testing by NASA. The design was refined based on feedback and testing, ultimately finalizing a prototype that balanced functionality and comfort. This prototype is currently being tested at NASA's Johnson Space Center.