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.

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.