Miles Zarick

Designer and Artist

About

ExoFlex Exercise Harness for NASA 

2025

Designed with NASA for the TCC Wearables Workshop

The ExoFlex Harness offers a novel solution to help astronauts work out in space more effectively and comfortably.

By redirecting the applied force from exercise machines, the ExoFlex prevents pain and chafing points.
Front View in Use
Back View 
Front View 
Back View 

Our solution seamlessly blends an array of materials such as Kydex, stainless steel, foam, fabric, and force resistance sensors to create a comfortable experience for the astronaut without compromising strength.

The Kydex plates and exoskeleton efficiently distribute the applied force from the exercise machines, such as the ARED, throughout the body.

The ladder locks offer adjustability for astronauts of all sizes. Comfortably fitting users between 5’ 2” and 6’ 4”, the limits of astronauts height.
Illustrator Sketch


Material Layering Expanded View
Embedded Sensors in Foam

FSR sensors are located at the shoulders and waist of the harness to determine optimal load distribution between the hips and shoulders.



Adjustable Fidlock Buckle
Pad Eye D-Ring for 360°  Movement
Kydex Side Plate     
                         
Cables are clipped into Pad-eye D-rings, allowing the cables to pivot, which offers mobility and strength.




Initial Concepts:

1. Central Connection Concept
Mock-up Front
Mock-up Back
Sketch Front                  Sketch Back                  Sketch 3/4

2. Exo-Frame Concept

Mock-up Front
Mock-up Back
Sketch Front                  Sketch Back                  Sketch 3/4


After our Second meeting with NASA, they decided to move forward with the Exo-frame concept and integrate geometry from the Central Connection concept for comfort.





Prototype Refinement

Prototype 1 Front
Prototype 2 Front
Prototype 3 Front







Force Testing Prototypes



Fabrication Process

We used an industrial sewing machine to construct all prototypes. The exoskeleton and connection plates were cut using CNC, then shaped with a heat gun.




NASA Johnson Space Center presentation
Working with engineers Mr. Christopher Beck and Ms. Kaitlin Lostroscio at NASA informed the struggles and requirements of an optimal exercise harness for the future. 

It was a pleasure to present this project at the TCC Wearable Workshop hosted by NASA at the Johnson Space Center.