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The pressurized capsule structure provides the pressure environment for astronauts or payloads in space, which is thus considered as the most crucial structural component for manned spacecraft. The manned deep space exploration mission (MDSEM) brings new challenges to the pressurized capsule structure: extremely low structural weight, long service life, reusability and adaptability to the harsh deep space environment. The conventional welded panel pressurized capsule structure (WPPCS) is not able to meet these new requirements. To address the above challenges, this paper comprehensively expounds why the current WPPCS cannot meet the requirements of MDSEMs based on the analysis of the vibration environment and structural characteristics of the pressurized capsule structure. Furthermore, a new type of integrated panel pressurized capsule structure (IPPCS) is proposed, showing the lightweight advantage compared with WPPCS. Finally, the technical details and research results of the strength criterion, design method, material upgrading and structural integrity manufacturing process of the IPPCS are fully introduced. The conclusions drawn in this paper will provide useful and meaningful references for the future development of large-size, lightweight pressurized capsule structures.

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