<font color="yellow">"Can lighter, stronger bulkheads be made from todays technology? New alloys, nanotech, composites? "</font><br /><br />Beryllium would likely not be used for a modern Gemini's heat shielding -- lighter and better shielding has since been developed. Titanium remains a strong contender, however. It's light, strong, and resistant to high temps.<br /><br />However -- the structure itself isn't something I've been targeting for reducing weight on (saving the primary heat shield as mentioned earlier in the thread). Using modern electronics and optimizing the Gemini-3X for space-station operations provides for massive weight reductions. <br /><br />Using modern electronics and eliminating the duplication caused by not having an expendable equipment module will slash the weight by several hundred pounds. Eliminating the fuel cells, water and food supplies, seat catapults, and other components will save close to a thousand pounds.<br /><br />Also -- while the original Gemini was pushing the limits of the Titan II -- the additional payload capacity of the Falcon V along with the weight reductions means that there is a significant reserve. I've actually shifted from focusing specifically on reducing weight to focusing on specific components -- preferably COTS -- that could be used as-is, or modified for use with a modern Gemini. Ideally I'd like to be able to come up with a laundry list of components that could be used to replace as many of the original Gemini subsystems as possible.