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Design a spacesuit

Design a spacesuit
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Build a wearable model spacesuit using cardboard, foil, fabric, and tape. Test movement, insulation ideas, and learn about astronaut life.

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Step-by-step guide to design a spacesuit

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Space Suit Explained : How It Keeps Astronauts Alive | What Is a Space Suit ?

What you need
Adult supervision required, aluminum foil, cardboard sheets, colouring materials, elastic bands or velcro strips, fabric scraps, marker, ruler, scissors, small padding like cotton or sponge, tape

Step 1

Gather all the materials on a clear table so you can reach everything easily.

Step 2

Measure the child’s chest width and torso length with the ruler and say the numbers out loud.

Step 3

Draw front and back torso outlines on cardboard using the marker and the measurements.

Step 4

Cut out the cardboard front and back panels along your drawn lines.

Step 5

Cover the inside of each cardboard panel with aluminum foil to add an insulation layer.

Step 6

Tape the front and back panels together at the shoulders leaving the side seams open for arms.

Step 7

Cut two fabric tubes to match the child’s arm length to make sleeves.

Step 8

Tape each fabric sleeve into the arm openings on the cardboard torso.

Step 9

Make a helmet by cutting a cardboard circle and shaping it into a dome that fits the head.

Step 10

Wrap the helmet dome in aluminum foil and secure the edges with tape.

Step 11

Attach elastic bands or Velcro strips to the sides of the torso so the suit can be fastened on and off.

Step 12

Tape small padding pieces into the elbows knees and back for comfort and extra insulation.

Step 13

Put the spacesuit on with an adult’s help so everything fits securely.

Step 14

Walk five steps while wearing the suit to test movement and notice any tight or loose spots.

Step 15

Share your finished spacesuit creation on DIY.org

Final steps

You're almost there! Complete all the steps, bring your creation to life, post it, and conquer the challenge!

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Help!?

What can we use if we don't have aluminum foil or the right fabric for the sleeves?

If aluminum foil isn't available to cover the cardboard panels for insulation, substitute a reflective emergency blanket, bubble wrap, or foam sheets, and if you don't have fabric for the arm tubes use old t-shirts, pillowcases, or cut-up sweatpants to make the sleeves.

The shoulder seams or taped sides keep coming apart when the child walks—how can we fix that?

If taped shoulder seams or side openings tear during the five-step movement test, reinforce them by gluing an extra small cardboard patch inside each seam and wrapping strong duct tape around the exterior joints for added strength.

How can we adapt the activity for different ages so it stays safe and fun?

For preschoolers have an adult do the measuring, pre-cut the cardboard front/back panels and helmet dome, and use soft foam or pre-made sleeves, while older kids can measure aloud, draw and cut their own outlines, and attach Velcro and lights themselves.

How can we make the spacesuit more realistic or personalized after it's assembled?

To enhance the suit, paint or add stickers to the cardboard panels, glue battery-powered LED lights around the helmet dome, tape a painted plastic bottle as a faux oxygen tank to the back using the Velcro strips, and add extra padding at elbows, knees, and back for comfort and style.

Watch videos on how to design a spacesuit

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The Science Behind NASA's Astronaut Spacesuits Explained | WION Podcast

4 Videos

Facts about space science and engineering for kids

✨ Shiny materials such as Mylar and aluminum foil reflect radiant heat, which is why emergency blankets and suit layers look metallic.

🌊 Astronauts practice spacewalks underwater in giant pools to simulate weightlessness and test how suits affect mobility.

📦 Cardboard is awesome for prototyping wearable parts—it's light, easy to cut and bend, and great for testing movement and fit.

🌞 In low Earth orbit, surfaces in sunlight can exceed +120°C while shaded areas can drop below −150°C, so insulation matters a lot.

🧑‍🚀 Modern NASA spacesuits (like the EMU) can have about 14 layers to protect against micrometeoroids, temperature, and vacuum.

How do you build a wearable cardboard and foil spacesuit model?

Start by measuring your child and cutting a cardboard box to fit as a torso piece; cut arm and head openings. Cover the cardboard with aluminum foil for a reflective layer, then add fabric panels at joints for flexibility. Use tape and Velcro to fasten seams and allow removal. Add insulated inserts (bubble wrap or quilt batting) in pockets to test warmth. Have the child move, sit, and reach, then adjust for range of motion.

What materials do I need to make a wearable spacesuit for kids?

You'll need cardboard boxes or poster board, aluminum foil, fabric scraps or old clothing, duct tape, masking tape, scissors (adult use for sturdy cuts), Velcro strips or elastic bands, measuring tape, markers and paint for decorating, bubble wrap or batting for insulation, safety pins or hot glue (adult-only), and optional craft foam for helmet pieces. Keep small items like buttons or beads out for young children to avoid choking hazards.

What ages is the spacesuit design activity suitable for?

This activity suits preschoolers to teens with different levels of adult help. Ages 4–6 can make a simple vest or cape with heavy supervision for cutting and taping. Ages 7–10 can design more detailed suits with fabric panels and basic fasteners. Ages 11+ can add sewn seams, helmet mock-ups, and insulation tests independently. Always supervise use of sharp tools, hot glue, and small parts, and adapt complexity to your child's coordination.

What are safety tips and learning benefits of designing a model spacesuit?

Safety first: use rounded safety scissors, avoid loose strings that could tangle, and never seal the suit tightly over the face. Supervise adhesive and cutting, and keep small parts away from toddlers. Educational benefits include hands-on learning about insulation, mobility, and astronaut life, boosting problem-solving, creativity, and teamwork. Variations: turn it into a timed engineering challenge, add simple thermometers to test insulation, or make matching family suits for role play.
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