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With Trump’s cutbacks, crew heads for ISS unsure of when they’ll come back

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“We are looking at the potential to extend this current flight, Crew-11.”

NASA astronaut Zena Cardman departs crew quarters at Kennedy Space Center, Florida, for the ride to SpaceX’s launch pad. Credit: Miguel J. Rodriguez Carrillo/Getty Images

The next four-person team to live and work aboard the International Space Station departed from NASA’s Kennedy Space Center in Florida on Friday, taking aim at the massive orbiting research complex for a planned stay of six to eight months.

Spacecraft commander Zena Cardman leads the mission, designated Crew-11, that lifted off from Florida’s Space Coast at 11: 43 am EDT (15: 43 UTC) on Friday. Sitting to her right inside SpaceX’s Crew Dragon Endeavour capsule was veteran NASA astronaut Mike Fincke, serving as the vehicle pilot. Flanking the commander and pilot were two mission specialists: Kimiya Yui of Japan and Oleg Platonov of Russia.

Cardman and her crewmates rode a Falcon 9 rocket off the launch pad and headed northeast over the Atlantic Ocean, lining up with the space station’s orbit to set the stage for an automated docking at the complex early Saturday.

Goodbye LZ-1

The Falcon 9’s reusable first stage booster detached and returned to a propulsive touchdown at Landing Zone 1 (LZ-1) at Cape Canaveral Space Force Station, a few miles south of the launch site. This was the 53rd and final rocket landing at LZ-1 since SpaceX aced the first intact recovery of a Falcon 9 booster there on December 21, 2015.

On most of SpaceX’s missions, Falcon 9 boosters land on the company’s offshore drone ships hundreds of miles downrange from the launch site. For launches with enough fuel margin, the first stage can return to an onshore landing. But the Space Force, which leases out the landing zones to SpaceX, wants to convert the site of LZ-1 into a launch site for another rocket company.

SpaceX will move onshore rocket landings to new landing zones to be constructed next to the two Falcon 9 launch pads at the Florida spaceport. Landing Zone 2, located adjacent to Landing Zone 1, will also be decommissioned and handed back over to the Space Force once SpaceX activates the new landing sites.

“We’re working with the Cape and with the Kennedy Space Center folks to figure out the right time to make that transition from Landing Zone 2 in the future,” said Bill Gerstenmaier, SpaceX’s vice president of build and flight reliability. “But I think we’ll stay with Landing Zone 2 at least near-term, for a little while, and then look at the right time to move to the other areas.”

The Falcon 9 booster returns to Landing Zone 1 after the launch of the Crew-11 mission on Friday, August 1, 2025. Credit: SpaceX

Meanwhile, the Falcon 9’s second stage fired its single engine to accelerate the Crew Dragon spacecraft into low-Earth orbit. Less than 10 minutes after liftoff, the capsule separated from the second stage to wrap up the 159th consecutive successful launch of a Falcon 9 rocket.

“I have no emotions but joy right now,” Cardman said moments after arriving in orbit. “That was absolutely transcendent, the ride of a lifetime.”

This is the first trip to space for Cardman, a 37-year-old geobiologist and Antarctic explorer selected as a NASA astronaut in 2017. She was assigned to command a Dragon flight to the ISS last year, but NASA bumped her and another astronaut from the mission to make room for the spacecraft to return the two astronauts left behind on the station by Boeing’s troubled Starliner capsule.

Mike Fincke, 58, is beginning his fourth spaceflight after previous launches on Russian Soyuz spacecraft and NASA’s space shuttle. He was previously training to fly on the Starliner spacecraft’s first long-duration mission, but NASA moved him to Dragon as the Boeing program faced more delays.

“Boy, it’s great to be back in orbit!” Fincke said. “Thank you to SpaceX and NASA for getting us here. What a ride!”

Yui is on his second flight to orbit. The 55-year-old former fighter pilot in the Japanese Air Self-Defense Force spent 141 days in space in 2015. Platonov, a 39-year-old spaceflight rookie, was a fighter pilot in the Russian Air Force before training to become a cosmonaut.

A matter of money

There’s some unexpected uncertainty going into this mission about how long the foursome will be in space. Missions sometimes get extended for technical reasons, or because of poor weather in recovery zones on Earth, but there’s something different in play with Crew-11. For the first time, there’s a decent chance that NASA will stretch out this expedition due to money issues.

The Trump administration has proposed across-the-board cuts to most NASA programs, including the International Space Station. The White House’s budget request for NASA in fiscal year 2026, which begins on October 1, calls for an overall cut in agency funding of nearly 25 percent.

The White House proposes a slightly higher reduction by percentage for the International Space Station and crew and cargo transportation to and from the research outpost. The cuts to the ISS would keep the station going through 2030, but with a smaller crew and a reduced capacity for research. Effectively, the ISS would limp toward retirement after more than 30 years in orbit.

Steve Stich, NASA’s commercial crew program manager, said the agency’s engineers are working with SpaceX to ensure the Dragon spacecraft can stay in orbit for at least eight months. The current certification limit is seven months, although officials waived the limit for one Dragon mission that lasted longer.

“When we launch, we have a mission duration that’s baseline,” Stich said in a July 10 press conference. “And then we can extend [the] mission in real-time, as needed, as we better understand… the reconciliation bill and the appropriations process and what that means relative to the overall station manifest.”

An update this week provided by Dana Weigel, NASA’s ISS program manager, indicated that officials are still planning for Crew-11 to stay in space a little longer than usual.

“We are looking at the potential to extend this current flight, Crew-11,” Weigel said Wednesday. “There are a few more months worth of work to do first.”

This photo of the International Space Station was captured by a crew member on a Soyuz spacecraft. Credit: NASA/Roscosmos

Budget bills advanced in the Senate and House of Representatives in July would maintain funding for most NASA programs, including the ISS and transportation, close to this year’s levels. But it’s no guarantee that Congress will pass an appropriations bill for NASA before the deadline of midnight on October 1. It’s also unknown whether President Donald Trump would sign a budget bill into law that rejects his administration’s cuts.

If Congress doesn’t act, lawmakers must pass a continuing resolution as a temporary stopgap measure or accept a government shutdown. Some members of Congress are also concerned that the Trump administration might simply refuse to spend money allotted to NASA and other federal agencies in any budget bill. This move, called impoundment, would be controversial, and its legality would likely have to be adjudicated in the courts.

A separate amendment added in Congress to a so-called reconciliation bill and signed into law by Trump on July 4 also adds $1.25 billion for ISS operations through 2029. “We’re still evaluating how that’s going to affect operations going forward, but it’s a positive step,” said Ken Bowersox, NASA’s associate administrator for space operations.

Suffice it to say that while Congress has signaled its intention to keep funding the ISS and many other NASA programs, the amount of money the space agency will actually receive remains uncertain. Trump appointees have directed NASA managers to prepare to operate as if the White House’s proposed cuts will become reality.

For officials in charge of the International Space Station, this means planning for fewer astronauts, reductions in research output, and longer-duration missions to minimize the number of crew rotation flights NASA must pay for. SpaceX is NASA’s primary contractor for crew rotation missions, using its Dragon spacecraft. NASA has a similar contract with Boeing, but that company’s Starliner spacecraft has not been certified for any operational flights to the station.

SpaceX’s next crew mission to the space station, Crew-12, is scheduled to launch early next year. Weigel said NASA is looking at the “entire spectrum” of options to cut back on the space station’s operations and transportation costs. One of those options would be to launch three crew members on Crew-12 instead of the regular four-person complement.

“We don’t have to answer that right now,” Weigel said. “We can actually wait pretty late to make the crew size smaller if we need to. In terms of cargo vehicles, we’re well-supplied through this fall, so in the short term, I’d say, through the end of this year and the beginning of ’26, things look pretty normal in terms of what we have planned for the program.

“But we’re evaluating things, and we’ll be ready to adjust when the budget is passed and when we figure out where we really land.”

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Stephen Clark is a space reporter at Ars Technica, covering private space companies and the world’s space agencies. Stephen writes about the nexus of technology, science, policy, and business on and off the planet.

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The ISS is nearing retirement, so why is NASA still gung-ho about Starliner?

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NASA is doing all it can to ensure Boeing doesn’t abandon the Starliner program.

Boeing’s Starliner spacecraft atop a United Launch Alliance Atlas V rocket before a test flight in 2019. Credit: NASA/Joel Kowsky

Boeing’s Starliner spacecraft atop a United Launch Alliance Atlas V rocket before a test flight in 2019. Credit: NASA/Joel Kowsky

After so many delays, difficulties, and disappointments, you might be inclined to think that NASA wants to wash its hands of Boeing’s troubled Starliner spacecraft.

But that’s not the case.

The manager of NASA’s commercial crew program, Steve Stich, told reporters Thursday that Boeing and its propulsion supplier, Aerojet Rocketdyne, are moving forward with several changes to the Starliner spacecraft to resolve problems that bedeviled a test flight to the International Space Station (ISS) last year. These changes include new seals to plug helium leaks and thermal shunts and barriers to keep the spacecraft’s thrusters from overheating.

Boeing, now more than $2 billion in the hole to pay for all Starliner’s delays, is still more than a year away from executing on its multibillion-dollar NASA contract and beginning crew rotation flights to the ISS. But NASA officials say Boeing remains committed to Starliner.

“We really are working toward a flight as soon as early next year with Starliner, and then ultimately, our goal is to get into crew rotation flights with Starliner,” Stich said. “And those would start no earlier than the second crew rotation slot at the end of next year.”

That would be 11 years after Boeing officials anticipated the spacecraft would enter operational service for NASA when they announced the Starliner program in 2010.

Decision point

The next Starliner flight will probably transport only cargo to the ISS, not astronauts. But NASA hasn’t made any final decisions on the matter. The agency has enough crew rotation missions booked to fly on SpaceX’s Dragon spacecraft to cover the space station’s needs until well into 2027 or 2028.

“I think there are a lot of advantages, I would say, to fly the cargo flight first,” Stich said. “If we really look at the history of Starliner and Dragon, I think Dragon benefited a lot from having earlier [cargo] flights before the crew contract was let for the space station.”

One drawback of flying a Starliner cargo mission is that it will use up one of United Launch Alliance’s remaining Atlas V rockets currently earmarked for a future Starliner crew launch. That means Boeing would have to turn to another rocket to accomplish its full contract with NASA, which covers up to six crew missions.

While Boeing says Starliner can launch on several different rockets, the difficulty of adapting the spacecraft to a new launch vehicle, such as ULA’s Vulcan, shouldn’t be overlooked. Early in Starliner’s development, Boeing and ULA had to overcome an issue with unexpected aerodynamic loads discovered during wind tunnel testing. This prompted engineers to design an aerodynamic extension, or skirt, to go underneath the Starliner spacecraft on top of its Atlas V launcher.

Starliner has suffered delays from the beginning. A NASA budget crunch in the early 2010s pushed back the program about two years, but the rest of the schedule slips have largely fallen on Boeing’s shoulders. The setbacks included a fuel leak and fire during a critical ground test, parachute problems, a redesign to accommodate unanticipated aerodynamic forces, and a computer timing error that cut short Starliner’s first attempt to reach the space station in 2019.

This all culminated in the program’s first test flight with astronauts last summer. But after running into helium leaks and overheating thrusters, the mission ended with Starliner returning to Earth empty, while the spacecraft’s two crew members remained on the International Space Station until they could come home on a SpaceX Dragon spacecraft this year.

The outcome was a stinging disappointment for Boeing. Going into last year’s crew test flight, Boeing appeared to be on the cusp of joining SpaceX and finally earning revenue as one of NASA’s certified crew transportation providers for the ISS.

For several months, Boeing officials were strikingly silent on Starliner’s future. The company declined to release any statements on their long-term commitment to the program, and a Boeing program manager unexpectedly withdrew from a NASA press conference marking the end of the Starliner test flight last September.

Kelly Ortberg, Boeing’s president and CEO, testifies before the Senate Commerce, Science, and Transportation Committee on April 2, 2025, in Washington, DC. Credit: Win McNamee/Getty Images

But that has changed in the last few months. Kelly Ortberg, who took over as Boeing’s CEO last year, told CNBC in April that the company planned “more missions on Starliner” and said work to overcome the thruster issues the spacecraft encountered last year is “pretty straightforward.”

“We know what the problems were, and we’re making corrective actions,” Ortberg said. “So, we hope to do a few more flights here in the coming years.”

Task and purpose

NASA officials remain eager for Starliner to begin these regular crew rotation flights, even as its sole destination, the ISS, enters its sunset years. NASA and its international partners plan to decommission and scuttle the space station in 2030 and 2031, more than 30 years after the launch of the lab’s first module.

NASA’s desire to bring Starliner online has nothing to do with any performance issues with SpaceX, the agency’s other commercial crew provider. SpaceX has met or exceeded all of NASA’s expectations in 11 long-duration flights to the ISS with its Dragon spacecraft. Since its first crew flight in 2020, SpaceX has established a reliable cadence with Dragon missions serving NASA and private customers.

However, there are some questions about SpaceX’s long-term plans for the Dragon program, and those concerns didn’t suddenly spring up last month, when SpaceX founder and chief executive Elon Musk suggested on X that SpaceX would “immediately” begin winding down the Dragon program. The suggestion came as Musk and President Donald Trump exchanged threats and insults on social media amid a feud as the one-time political allies had a dramatic falling out months into Trump’s second term in the White House.

In a subsequent post on X, Musk quickly went back on his threat to soon end the Dragon program. SpaceX officials participating in NASA press conferences in the last few weeks have emphasized the company’s dedication to human spaceflight without specifically mentioning Dragon. SpaceX’s fifth and final human-rated Dragon capsule debuted last month on its first flight to the ISS.

“I would say we’re pretty committed to the space business,” said Bill Gerstenmaier, SpaceX’s vice president of build and flight reliability. “We’re committed to flying humans in space and doing it safely.”

There’s a kernel of truth behind Musk’s threat to decommission Dragon. Musk has long had an appetite to move on from the Dragon program and pivot more of SpaceX’s resources to Starship, the company’s massive next-generation rocket. Starship is envisioned by SpaceX as an eventual replacement for Dragon and the Falcon 9 launcher.

A high-resolution commercial Earth-imaging satellite owned by Maxar captured this view of the International Space Station on June 7, 2024, with Boeing’s Starliner capsule docked at the lab’s forward port (lower right). Credit: Satellite image (c) 2024 Maxar Technologies

NASA hopes commercial space stations can take over for the ISS after its retirement, but there’s no guarantee SpaceX will still be flying Dragon in the 2030s. This injects some uncertainty into plans for commercial space stations.

One possible scenario is that, sometime in the 2030s, the only options for transporting people to and from commercial space stations in low-Earth orbit could be Starliner and Starship. We’ll discuss the rationale for this scenario later in this story.

While the cost of a seat on SpaceX’s Dragon is well known, there’s low confidence in the price of a ticket to low-Earth orbit on Starliner or Starship. What’s more, some of the commercial outposts may be incompatible with Starship because of its enormous mass, which could overcome the ability of a relatively modest space station to control its orientation. NASA identified this as an issue with its Gateway mini-space station in development to fly in orbit around the Moon.

It’s impossible to predict when SpaceX will pull the plug on Dragon. The same goes with Boeing and Starliner. But NASA and other customers are interested in buying more Dragon flights.

If SpaceX can prove Starship is safe enough to launch and land with people onboard, Dragon’s days will be numbered. But Starship is likely at least several years from being human-rated for flights to and from low-Earth orbit. NASA’s contract with SpaceX to develop a version of Starship to land astronauts on the Moon won’t require the ship to be certified for launches and landings on Earth. In some ways, that’s a more onerous challenge than the Moon mission because of the perils of reentering Earth’s atmosphere, which Starship won’t need to endure for a lunar landing, and the ship’s lack of a launch abort system.

Once operational, Starship is designed to carry significantly more cargo and people than Falcon 9 and Dragon, but it’s anyone’s guess when it might be ready for crew missions. Until then, if SpaceX wants to have an operational human spaceflight program, it’s Dragon or bust.

For the International Space Station, it’s also Dragon or bust, at least until Boeing gets going. SpaceX’s capsules are the only US vehicles certified to fly to space with NASA astronauts, and any more US government payments to Russia to launch Americans on Soyuz missions would be politically unpalatable.

From the start of the commercial crew program, NASA sought two contractors providing their own means of flying to and from the ISS. The main argument for this “dissimilar redundancy” was to ensure NASA could still access the space station in the event of a launch failure or some other technical problem. The same argument could be made now that NASA needs two options to avoid being at the whim of one company’s decisions.

Stretching out

All of this is unfolding as the Trump administration seeks to slash funding for the International Space Station, cut back on the lab’s research program, and transition to “minimal safe operations” for the final few years of its life. Essentially, the space station would limp to the finish line, perhaps with a smaller crew than the seven-person staff living and working in it today.

At the end of this month, SpaceX is scheduled to launch the Crew-11 mission—the 12th Dragon crew mission for NASA and the 11th fully operational crew ferry flight to the ISS. Two Americans, one Japanese astronaut, and a Russian cosmonaut will ride to the station for a stay of at least six months.

NASA’s existing contract with SpaceX covers four more long-duration flights to the space station with Dragon, including the mission set to go on July 31.

One way NASA can save money in the space station’s budget is by simply flying fewer missions. Stich said Thursday that NASA is working with SpaceX to extend the Dragon spacecraft’s mission duration limit from seven months to eight months. The recertification of Dragon for a longer mission could be finished later this year, allowing NASA to extend Crew-11’s stay at the ISS if needed. Over time, longer stays mean fewer crew rotation missions.

“We can extend the mission in real-time as needed as we better understand… the appropriations process and what that means relative to the overall station manifest,” Stich said.

Boeing’s Starliner spacecraft backs away from the International Space Station on September 6, 2024, without its crew. Credit: NASA

Boeing’s fixed-price contract with NASA originally covered an unpiloted test flight of Starliner, a demonstration flight with astronauts, and then up to six operational missions delivering crews to the ISS. But NASA has only given Boeing the “Authority To Proceed” for three of its six potential operational Starliner missions. This milestone, known as ATP, is a decision point in contracting lingo where the customer—in this case, NASA—places a firm order for a deliverable. NASA has previously said it awards these task orders about two to three years prior to a mission’s launch.

If NASA opts to go to eight-month missions on the ISS with Dragon and Starliner, the agency’s firm orders for three Boeing missions and four more SpaceX crew flights would cover the agency’s needs into early 2030, not long before the final crew will depart the space station.

Stich said NASA officials are examining their options. These include whether NASA should book more crew missions with SpaceX, authorize Boeing to prepare for additional Starliner flights beyond the first three, or order no more flights at all.

“As we better understand the budget and better understand what’s in front of us, we’re working through that,” Stich said. “It’s really too early to speculate how many flights we’ll fly with each provider, SpaceX and Boeing.”

Planning for the 2030s

NASA officials also have an eye for what happens after 2030. The agency has partnered with commercial teams led by Axiom, Blue Origin, and Voyager Technologies on plans for privately owned space stations in low-Earth orbit to replace some of the research capabilities lost with the end of the ISS program.

The conventional wisdom goes that these new orbiting outposts will be less expensive to operate than the ISS, making them more attractive to commercial clients, ranging from pharmaceutical research and in-space manufacturing firms to thrill-seeking private space tourists. NASA, which seeks to maintain a human presence in low-Earth orbit as it turns toward the Moon and Mars, will initially be an anchor customer until the space stations build up more commercial demand.

These new space stations will need a way to receive cargo and visitors. NASA wants to preserve the existing commercial cargo and crew transport systems so they’re available for commercial space stations in the 2030s. Stich said NASA is looking at transferring the rights for any of the agency’s commercial crew missions that don’t fly to ISS over to the commercial space stations. Among NASA’s two commercial crew providers, it currently looks more likely that Boeing’s contract will have unused capacity than SpaceX’s when the ISS program ends.

This is a sweetener NASA could offer to its stable of private space station developers as they face other hurdles in getting their hardware off the ground. It’s unclear whether a business case exists to justify the expense of building and operating a commercial outpost in orbit or if the research and manufacturing customers that could use a private space station might find a cheaper option in robotic flying laboratories, such as those being developed by Varda Space Industries.

A rendering of Voyager’s Starlab space station. Credit: Voyager Space

NASA’s policies haven’t helped matters. Analysts say NASA’s financial support for private space station developers has lagged, and the agency’s fickle decision-making on when to retire the International Space Station has made private fundraising more difficult. It’s not a business for the faint-hearted. For example, Axiom has gone through several rounds of layoffs in the last year.

The White House’s budget request for fiscal year 2026 proposes a 25 percent cut to NASA’s overall budget, but the funding line for commercial space stations is an area marked for an increase. Still, there’s a decent chance that none of the proposed commercial outposts will be flying when the ISS crashes back to Earth. In that event, China would be the owner and operator of the only space station in orbit.

At least at first, transportation costs will be the largest expense for any company that builds and operates a privately owned space station. It costs NASA about 40 percent more each year to ferry astronauts and supplies to and from the ISS than it does to operate the space station. For a smaller commercial outpost with reduced operating costs, the gap will likely be even wider.

If Boeing can right the ship with Starliner and NASA offers a few prepaid crew missions to private space station developers, the money saved could help close someone’s business case and hasten the launch of a new era in commercial spaceflight.

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Stephen Clark is a space reporter at Ars Technica, covering private space companies and the world’s space agencies. Stephen writes about the nexus of technology, science, policy, and business on and off the planet.

The ISS is nearing retirement, so why is NASA still gung-ho about Starliner? Read More »

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Boeing is still bleeding money on the Starliner commercial crew program

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“We signed up to some things that are problematic.”

Boeing’s Starliner spacecraft backs away from the International Space Station on September 6 without its crew. Credit: NASA

Sometimes, it’s worth noting when something goes unsaid.

On Wednesday, Boeing’s new CEO, Kelly Ortberg, participated in his first quarterly conference call with investment analysts. Under fire from labor groups and regulators, Boeing logged a nearly $6.2 billion loss for the last three months, while the new boss pledged a turnaround for the troubled aerospace company.

What Ortberg didn’t mention in the call was the Starliner program. Starliner is a relatively small portion of Boeing’s overall business, but it’s a high-profile and unprofitable one.

Mounting losses

Boeing has reported recurring financial losses on the program and added $250 million to the tally with Wednesday’s quarterly report filed with the Securities and Exchange Commission. This brings the company’s total losses on Starliner to $1.85 billion, recorded in increments over the last few years as the program has faced technical problems and delays.

In its SEC filing, Boeing wrote: “Risk remains that we may record additional losses in future periods.”

Boeing runs the Starliner program under a fixed-price contract with NASA, meaning the government pays the contractor a set amount of money, and the company is on the hook for any cost overruns. These are favorable terms for the government because they divert financial risk to the contractor, usually resulting in lower costs if the program is successful.

Since the last Starliner test flight ended in a disappointing fashion, Boeing has released no updates on its plans for the future of the spacecraft. The company released a short written statement after Starliner landed in early September, saying managers would review data and “determine the next steps for the program.”

A week after Starliner landed, Boeing’s chief financial officer, Brian West, echoed that line. “There is important work to determine any next steps for the Starliner program, and we’ll evaluate that,” he said at a conference sponsored by Morgan Stanley.

A member of the Starliner recovery team removes cargo from the spacecraft after landing in New Mexico on September 6, without its two-person crew.

Credit: NASA/Aubrey Gemignani

A member of the Starliner recovery team removes cargo from the spacecraft after landing in New Mexico on September 6, without its two-person crew. Credit: NASA/Aubrey Gemignani

Starliner concluded its third test flight a little more than six weeks ago, leaving behind the two astronauts the craft ferried to the International Space Station earlier in the year. This was the first time people flew into orbit on a Starliner spacecraft.

NASA, which partnered with Boeing to develop the Starliner spacecraft, decided the Boeing capsule should return to Earth without its crew after the test flight encountered problems with overheating thrusters and helium leaks. The spacecraft safely reached the space station with NASA astronauts Butch Wilmore and Suni Williams in June, but agency officials were not comfortable with risking the crew’s safety on Starliner for the trip home. Instead, the duo will return to Earth on a SpaceX Dragon spacecraft early next year.

Boeing managers had a different opinion and lobbied for Starliner to return to Earth with Wilmore and Williams. Ultimately, the Starliner spacecraft parachuted to a successful landing at White Sands Space Harbor, New Mexico, on September 6, but there’s a lot of work ahead for Boeing to fix the thruster problems and helium leaks before the capsule can fly with people again. This will take many months—potentially a year or more—and will cost Boeing hundreds of millions of dollars, as shown in Wednesday’s SEC filing.

Doing less

In response to questions Wednesday from Wall Street investment firms, Ortberg, who took the CEO job in August, suggested it’s time for Boeing to look at cutting some of its losses and recalibrate how it pursues new business opportunities. Boeing’s previous CEO, Dave Calhoun, said last year the company would no longer enter into fixed-price development contracts.

“I think that that we’re better off being doing less and doing it better than doing more and not doing it well,” Ortberg said. “So we’re in the process of taking an evaluation of the portfolio. It’s something a new CEO always does when you come into a business.”

Most of Boeing’s financial loss in the third quarter of this year came from the company’s commercial airplane business. Beset by safety concerns with its 737 Max aircraft and a labor strike that has halted production at many of its airplane factories, Boeing posted its worst quarterly performance since the height of the COVID pandemic in 2020.

Even before the strike, the Federal Aviation Administration capped Boeing’s production rate for the 737 Max, limiting revenue for the commercial airplane business.

Ortberg didn’t specify any programs that Boeing might consider trimming or canceling, but said the company’s “core” business of commercial airplanes and military systems will stay.

“There are probably some things on the fringe there that we can be more efficient with, or that just distract us from our main goal here. So, more to come on that,” Ortberg said. “I don’t have a specific list of things that we’re going to keep and we’re not going to keep. That’s something for us to evaluate, and the process is underway.”

Kelly Ortberg, Boeing’s new CEO, is pictured in 2016 during his tenure as chief executive of Rockwell Collins.

Kelly Ortberg, Boeing’s new CEO, is pictured in 2016 during his tenure as chief executive of Rockwell Collins. Credit: Daniel Acker/Bloomberg via Getty Images

Apart from technical execution, Ortberg identified Boeing’s errors in cost and risk estimation as other reasons for the company’s poor performance on several fixed-price government contracts, including Starliner.

“We’re not going to be able to just wave the wand and clean up these troubled contracts,” he said. “We signed up to some things that are problematic.”

Ortberg said he is reluctant to ditch all of Boeing’s troubled contracts. “Even if we wanted to, I don’t think we can walk away from these contracts,” he said. “These are our core customers that need this capability. We’ve got long-term commitments to them. So walking away isn’t an answer to this.”

However, Orberg added that Boeing could reassess programs as they shift from one contract phase to the next. NASA’s commercial crew contract with Boeing has a maximum value of $4.6 billion, but that assumes the agency gives Boeing the green light to fly six operational Starliner missions.

So far, NASA has only authorized Boeing to begin detailed preparations for three. The latter half of the commercial crew contract remains a question mark, and could be an opportunity for Boeing to reevaluate the Starliner program without breaking its obligations to NASA. This is especially salient because NASA plans to decommission the International Space Station in 2030, and it’s not clear Boeing could fly all six of its Starliner missions before then while still alternating with SpaceX for crew transportation duties.

“We do have to get into a position where we’ve got a portfolio much more balanced with less risky programs and more profitable programs, and we’re going to be working that,” Ortberg said. “But I don’t think a wholesale walkaway is in the cards.”

This statement makes it sound like Boeing isn’t going to pull the plug on Starliner immediately. Still, Boeing hasn’t laid out its specific plans for Starliner, or even confirmed its intention to keep working on the program. This is puzzling.

Saying nothing

Ortberg was not asked about Starliner in Wednesday’s investor call. After the call, Ars asked a Boeing spokesperson if the company still has a long-term commitment to the Starliner program. The spokesperson replied that the company has nothing to share on the topic.

The Starliner test flight this year was supposed to pave the way for NASA to officially certify the Boeing crew capsule to begin flying in a slate of up to six operational crew rotation flights to the space station. Once certified, Boeing will become NASA’s second crew transportation provider alongside SpaceX, which has now launched nine operational crew missions for NASA, plus a handful more all-private astronaut missions.

NASA still wants to certify Boeing’s Starliner spacecraft to provide the agency with a second commercial option for getting astronauts into orbit. A fundamental goal set out for NASA’s commercial crew program more than a decade ago was to develop two dissimilar human-rated transportation systems for access to low-Earth orbit. The idea here is competition will drive down costs, and NASA will have a backup option if one of the commercial crew providers runs into difficulties.

However, NASA has not announced whether it will require Boeing to complete another test flight to achieve the certification milestone with Starliner. NASA is looking at slots to fly an unpiloted Starliner spacecraft on a cargo mission to the space station next year, perhaps to verify modifications to the ship’s propulsion system really fix the problems discovered on the test flight this year.

NASA is making moves while assuming Boeing will stay in the game. Astronauts are still assigned to train for the first operational Starliner mission, although it’s not likely to happen until the end of next year or in 2026. Earlier this month, NASA announced SpaceX will launch a four-person crew to the International Space Station no earlier than July of next year, taking a slot that the agency once hoped Boeing would use.

Bill Nelson, NASA’s administrator, told reporters in late August that he received assurances from Ortberg that Boeing intends to “move forward and fly Starliner in the future.” At the time, Ortberg was just a couple of weeks into his tenure at Boeing.

Two months later, Nelson’s secondhand assertion is still all we have.

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Stephen Clark is a space reporter at Ars Technica, covering private space companies and the world’s space agencies. Stephen writes about the nexus of technology, science, policy, and business on and off the planet.

Boeing is still bleeding money on the Starliner commercial crew program Read More »

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SpaceX launches mission to bring Starliner astronauts back to Earth

commercial crew, Commercial space, crew dragon, dragon, falcon 9, human spaceflight, international space station, launch, NASA, roscosmos, russia, Science, Space, spacex, starliner / /

Ch-ch-changes —

SpaceX is bringing back propulsive landings with its Dragon capsule, but only in emergencies.

– Updated

SpaceX's Crew Dragon spacecraft climbs away from Cape Canaveral Space Force Station, Florida, on Saturday atop a Falcon 9 rocket.

Enlarge / SpaceX’s Crew Dragon spacecraft climbs away from Cape Canaveral Space Force Station, Florida, on Saturday atop a Falcon 9 rocket.

NASA/Keegan Barber

NASA astronaut Nick Hague and Russian cosmonaut Aleksandr Gorbunov lifted off Saturday from Florida’s Space Coast aboard a SpaceX Dragon spacecraft, heading for a five-month expedition on the International Space Station.

The two-man crew launched on top of SpaceX’s Falcon 9 rocket at 1: 17 pm EDT (17: 17 UTC), taking an advantage of a break in stormy weather to begin a five-month expedition in space. Nine kerosene-fueled Merlin engines powered the first stage of the flight on a trajectory northeast from Cape Canaveral Space Force Station, then the booster detached and returned to landing at Cape Canaveral as the Falcon 9’s upper stage accelerated SpaceX’s Crew Dragon Freedom spacecraft into orbit.

“It was a sweet ride,” Hague said after arriving in space. With a seemingly flawless launch, Hague and Gorbunov are on track to arrive at the space station around 5: 30 pm EDT (2130 UTC) Sunday.

Empty seats

This is SpaceX’s 15th crew mission since 2020, and SpaceX’s 10th astronaut launch for NASA, but Saturday’s launch was unusual in a couple of ways.

“All of our missions have unique challenges and this one, I think, will be memorable for a lot of us,” said Ken Bowersox, NASA’s associate administrator for space operations.

First, only two people rode into orbit on SpaceX’s Crew Dragon spacecraft, rather than the usual complement of four astronauts. This mission, known as Crew-9, originally included Hague, Gorbunov, commander Zena Cardman, and NASA astronaut Stephanie Wilson.

But the troubled test flight of Boeing’s Starliner spacecraft threw a wrench into NASA’s plans. The Starliner mission launched in June with NASA astronauts Butch Wilmore and Suni Williams. Boeing’s spacecraft reached the space station, but thruster failures and helium leaks plagued the mission, and NASA officials decided last month it was too risky to being the crew back to Earth on Starliner.

NASA selected SpaceX and Boeing for multibillion-dollar commercial crew contracts in 2014, with each company responsible for developing human-rated spaceships to ferry astronauts to and from the International Space Station. SpaceX flew astronauts for the first time in 2020, and Boeing reached the same milestone with the test flight that launched in June.

Ultimately, the Starliner spacecraft safely returned to Earth on September 6 with a successful landing in New Mexico. But it left Wilmore and Williams behind on the space station with the lab’s long-term crew of seven astronauts and cosmonauts. The space station crew rigged two temporary seats with foam inside a SpaceX Dragon spacecraft currently docked at the outpost, where the Starliner astronauts would ride home if they needed to evacuate the complex in an emergency.

NASA astronaut Nick Hague and Russian cosmonaut Aleksandr Gorbunov in their SpaceX pressure suits.

Enlarge / NASA astronaut Nick Hague and Russian cosmonaut Aleksandr Gorbunov in their SpaceX pressure suits.

NASA/Kim Shiflett

This is a temporary measure to allow the Dragon spacecraft to return to Earth with six people instead of the usual four. NASA officials decided to remove two of the astronauts from the next SpaceX crew mission to free up normal seats for Wilmore and Williams to ride home in February, when Crew-9 was already slated to end its mission.

The decision to fly the Starliner spacecraft back to Earth without its crew had several second order effects on space station operations. Managers at NASA’s Johnson Space Center in Houston had to decide who to bump from the Crew-9 mission, and who to keep on the crew.

Nick Hague and Aleksandr Gorbunov ended up keeping their seats on the Crew-9 flight. Hague originally trained as the pilot on Crew-9, and NASA decided he would take Zena Cardman’s place as commander. Hague, a 49-year-old Space Force colonel, is a veteran of one long-duration mission on the International Space Station, and also experienced a rare in-flight launch abort in 2018 due to a failure of a Russian Soyuz rocket.

NASA announced the original astronaut assignments for the Crew-9 mission in January. Cardman, a 36-year-old geobiologist, would have been the first rookie astronaut without test pilot experience to command a NASA spaceflight. Three-time space shuttle flier Stephanie Wilson, 58, was the other astronaut removed from the Crew-9 mission.

The decision on who to fly on Crew-9 was a “really close call,” said Bowersox, who oversees NASA’s spaceflight operations directorate. “They were thinking very hard about flying Zena, but in this situation, it made sense to have somebody who had at least one flight under their belt.”

Gorbunov, a 34-year-old Russian aerospace engineer making his first flight to space, moved over to take pilot’s seat in the Crew Dragon spacecraft, although he remains officially designated a mission specialist. His remaining presence on the crew was preordained because of an international agreement between NASA and Russia’s space agency that provides seats for Russian cosmonauts on US crew missions and US astronauts on Russian Soyuz flights to the space station.

Bowersox said NASA will reassign Cardman and Wilson to future flights.

NASA astronauts Suni Williams and Butch Wilmore, seen in their Boeing flight suits before their launch.

Enlarge / NASA astronauts Suni Williams and Butch Wilmore, seen in their Boeing flight suits before their launch.

Operational flexibility

This was also the first launch of astronauts from Space Launch Complex-40 (SLC-40) at Cape Canaveral, SpaceX’s busiest launch pad. SpaceX has outfitted the launch pad with the equipment necessary to support launches of human spaceflight missions on the Crew Dragon spacecraft, including a more than 200-foot-tall tower and a crew access arm to allow astronauts to board spaceships on top of Falcon 9 rockets.

SLC-40 was previously based on a “clean pad” architecture, without any structures to service or access Falcon 9 rockets while they were vertical on the pad. SpaceX also installed slide chutes to give astronauts and ground crews an emergency escape route away from the launch pad in an emergency.

SpaceX constructed the crew tower last year and had it ready for the launch of a Dragon cargo mission to the space station in March. Saturday’s launch demonstrated the pad’s ability to support SpaceX astronaut missions, which have previously all departed from Launch Complex-39A (LC-39A) at NASA’s Kennedy Space Center, a few miles north of SLC-40.

Bringing human spaceflight launch capability online at SLC-40 gives SpaceX and NASA additional flexibility in their scheduling. For example, LC-39A remains the only launch pad configured to support flights of SpaceX’s Falcon Heavy rocket. SpaceX is now preparing LC-39A for a Falcon Heavy launch October 10 with NASA’s Europa Clipper mission, which only has a window of a few weeks to depart Earth this year and reach its destination at Jupiter in 2030.

With SLC-40 now certified for astronaut launches, SpaceX and NASA teams are able to support the Crew-9 and Europa Clipper missions without worrying about scheduling conflicts. The Florida spaceport now has three launch pads certified for crew flights—two for SpaceX’s Dragon and one for Boeing’s Starliner—and NASA will add a fourth human-rated launch pad with the Artemis II mission to the Moon late next year.

“That’s pretty exciting,” said Pam Melroy, NASA’s deputy administrator. “I think it’s a reflection of where we are in our space program at NASA, but also the capabilities that the United States has developed.”

Earlier this week, Hague and Gorbunov participated in a launch day dress rehearsal, when they had the opportunity to familiarize themselves with SLC-40. The launch pad has the same capabilities as LC-39A, but with a slightly different layout. SpaceX also test-fired the Falcon 9 rocket Tuesday evening, before lowering the rocket horizontal and moving it back into a hangar for safekeeping as the outer bands of Hurricane Helene moved through Central Florida.

Inside the hangar, SpaceX technicians discovered sooty exhaust from the Falcon 9’s engines accumulated on the outside of the Dragon spacecraft during the test-firing. Ground teams wiped the soot off of the craft’s solar arrays and heat shield, then repainted portions of the capsule’s radiators around the edge of Dragon’s trunk section before rolling the vehicle back to the launch pad Friday.

“It’s important that the radiators radiate heat in the proper way to space, so we had to put some some new paint on to get that back to the right emissivity and the right reflectivity and absorptivity of the solar radiation that hit those panels so it will reject the heat properly,” said Bill Gerstenmaier, SpaceX’s vice president of build and flight reliability.

Gerstenmaier also outlined a new backup ability for the Crew Dragon spacecraft to safely splash down even if all of its parachutes fail to deploy on final descent back to Earth. This involves using the capsule’s eight powerful SuperDraco thrusters, normally only used in the unlikely instance of a launch abort, to fire for a few seconds and slow Dragon’s speed for a safe splashdown.

A hover test using SuperDraco thrusters on a prototype Crew Dragon spacecraft in 2015.

Enlarge / A hover test using SuperDraco thrusters on a prototype Crew Dragon spacecraft in 2015.

SpaceX

“The way it works is, in the case where all the parachutes totally fail, this essentially fires the thrusters at the very end,” Gerstenmaier said. “That essentially gives the crew a chance to land safely, and essentially escape the vehicle. So it’s not used in any partial conditions. We can land with one chute out. We can land with other failures in the chute system. But this is only in the case where all four parachutes just do not operate.”

When SpaceX first designed the Crew Dragon spacecraft more than a decade ago, the company wanted to use the SuperDraco thrusters to enable the capsule to perform propulsive helicopter-like landings. Eventually, SpaceX and NASA agreed to change to a more conventional parachute-assisted splashdown.

The SuperDracos remained on the Crew Dragon spacecraft to push the capsule away from its Falcon 9 rocket during a catastrophic launch failure. The eight high-thrust engines burn hydrazine and nitrogen tetroxide propellants that combust when making contact with one another.

The backup option has been activated for some previous commercial Crew Dragon missions, but not for a NASA flight, according to Gerstenmaier. The capability “provides a tolerable landing for the crew,” he added. “So it’s a true deep, deep contingency. I think our philosophy is, rather than have a system that you don’t use, even though it’s not maybe fully certified, it gives the crew a chance to escape a really, really bad situation.”

Steve Stich, NASA’s commercial crew program manager, said the emergency propulsive landing capability will be enabled for the return of the Crew-8 mission, which has been at the space station since March. With the arrival of Hague and Gorbunov on Crew-9—and the extension of Wilmore and Williams’ mission—the Crew-8 mission is slated to depart the space station and splash down in early October.

This story was updated after confirmation of a successful launch.

SpaceX launches mission to bring Starliner astronauts back to Earth Read More »

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In the room where it happened: When NASA nearly gave Boeing all the crew funding

Boeing, commercial crew, Features, reentry, Space, spacex / /

The story behind the story —

“In all my years of working with Boeing I never saw them sign up for additional work for free.”

–

But for a fateful meeting in the summer of 2014, Crew Dragon probably never would have happened.

Enlarge / But for a fateful meeting in the summer of 2014, Crew Dragon probably never would have happened.

SpaceX

This is an excerpt from Chapter 11 of the book REENTRY: SpaceX, Elon Musk and the Reusable Rockets that Launched a Second Space Age by our own Eric Berger. The book will be published on September 24, 2024. This excerpt describes a fateful meeting 10 years ago at NASA Headquarters in Washington, DC, where the space agency’s leaders met to decide which companies should be awarded billions of dollars to launch astronauts into orbit.

In the early 2010s, NASA’s Commercial Crew competition boiled down to three players: Boeing, SpaceX, and a Colorado-based company building a spaceplane, Sierra Nevada Corporation. Each had its own advantages. Boeing was the blue blood, with decades of spaceflight experience. SpaceX had already built a capsule, Dragon. And some NASA insiders nostalgically loved Sierra Nevada’s Dream Chaser space plane, which mimicked the shuttle’s winged design.

This competition neared a climax in 2014 as NASA prepared to winnow the field to one company, or at most two, to move from the design phase into actual development. In May of that year Musk revealed his Crew Dragon spacecraft to the world with a characteristically showy event at the company’s headquarters in Hawthorne. As lights flashed and a smoke machine vented, Musk quite literally raised a curtain on a black-and-white capsule. He was most proud to reveal how Dragon would land. Never before had a spacecraft come back from orbit under anything but parachutes or gliding on wings. Not so with the new Dragon. It had powerful thrusters, called SuperDracos, that would allow it to land under its own power.

“You’ll be able to land anywhere on Earth with the accuracy of a helicopter,” Musk bragged. “Which is something that a modern spaceship should be able to do.”

A few weeks later I had an interview with John Elbon, a long-time engineer at Boeing who managed the company’s commercial program. As we talked, he tut-tutted SpaceX’s performance to date, noting its handful of Falcon 9 launches a year and inability to fly at a higher cadence. As for Musk’s little Dragon event, Elbon was dismissive.

“We go for substance,” Elbon told me. “Not pizzazz.”

Elbon’s confidence was justified. That spring the companies were finalizing bids to develop a spacecraft and fly six operational missions to the space station. These contracts were worth billions of dollars. Each company told NASA how much it needed for the job, and if selected, would receive a fixed price award for that amount. Boeing, SpaceX, and Sierra Nevada wanted as much money as they could get, of course. But each had an incentive to keep their bids low, as NASA had a finite budget for the program. Boeing had a solution, telling NASA it needed the entire Commercial Crew budget to succeed. Because a lot of decision-makers believed that only Boeing could safely fly astronauts, the company’s gambit very nearly worked.

Scoring the bids

The three competitors submitted initial bids to NASA in late January 2014, and after about six months of evaluations and discussions with the “source evaluation board,” submitted their final bids in July. During this initial round of judging, subject-matter experts scored the proposals and gathered to make their ratings. Sierra Nevada was eliminated because their overall scores were lower, and the proposed cost not low enough to justify remaining in the competition. This left Boeing and SpaceX, with likely only one winner.

“We really did not have the budget for two companies at the time,” said Phil McAlister, the NASA official at the agency’s headquarters in Washington overseeing the Commercial Crew program. “No one thought we were going to award two. I would always say, ‘One or more,’ and people would roll their eyes at me.”

Boeing's John Elbon, center, is seen in Orbiter Processing Facility-3 at NASA's Kennedy Space Center in Florida in 2012.

Boeing’s John Elbon, center, is seen in Orbiter Processing Facility-3 at NASA’s Kennedy Space Center in Florida in 2012.

NASA

The members of the evaluation board scored the companies based on three factors. Price was the most important consideration, given NASA’s limited budget. This was followed by “mission suitability,” and finally, “past performance.” These latter two factors, combined, were about equally weighted to price. SpaceX dominated Boeing on price.

Boeing asked for $4.2 billion, 60 percent more than SpaceX’s bid of $2.6 billion. The second category, mission suitability, assessed whether a company could meet NASA’s requirements and actually safely fly crew to and from the station. For this category, Boeing received an “excellent” rating, above SpaceX’s “very good.” The third factor, past performance, evaluated a company’s recent work. Boeing received a rating of “very high,” whereas SpaceX received a rating of “high.”

While this makes it appear as though the bids were relatively even, McAlister said the score differences in mission suitability and past performance were, in fact, modest. It was a bit like grades in school. SpaceX scored something like an 88, and got a B; whereas Boeing got a 91 and scored an A. Because of the significant difference in price, McAlister said, the source evaluation board assumed SpaceX would win the competition. He was thrilled, because he figured this meant that NASA would have to pick two companies, SpaceX based on price, and Boeing due to its slightly higher technical score. He wanted competition to spur both of the companies on.

In the room where it happened: When NASA nearly gave Boeing all the crew funding Read More »

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Navy captains don’t like abandoning ship—but with Starliner, the ship left them

Boeing, commercial crew, Commercial space, international space station, NASA, Science, Space, starliner / /
NASA astronauts Butch Wilmore and Suni Williams wave to their families, friends, and NASA officials on their way to the launch pad June 5 to board Boeing's Starliner spacecraft.

Enlarge / NASA astronauts Butch Wilmore and Suni Williams wave to their families, friends, and NASA officials on their way to the launch pad June 5 to board Boeing’s Starliner spacecraft.

NASA astronauts Butch Wilmore and Suni Williams are no strangers to time away from their families. Both are retired captains in the US Navy, served in war zones, and are veterans of previous six-month stays on the International Space Station.

When they launched to the space station on Boeing’s Starliner spacecraft on June 5, the astronauts expected to be home in a few weeks, or perhaps a month, at most. Their minimum mission duration was eight days, but NASA was always likely to approve a short extension. Wilmore and Williams were the first astronauts to soar into orbit on Boeing’s Starliner spacecraft, a milestone achieved some seven years later than originally envisioned by Boeing and NASA.

However, the test flight fell short of all of its objectives. Wilmore and Williams are now a little more than three months into what has become an eight-month mission on the station. The Starliner spacecraft was beset by problems, culminating in a decision last month by NASA officials to send the capsules back to Earth without the two astronauts. Rather than coming home on Starliner, Wilmore and Williams will return to Earth in February on a SpaceX Dragon spacecraft.

Grateful for options

On Friday, the two astronauts spoke with reporters for the first time since NASA decided they would stay in orbit until early 2025.

“It was trying at times,” Wilmore said. There were some tough times all the way through. Certainly, as the commander or pilot of your spacecraft, you don’t want to see it go off without you, but that’s where we wound up.”

Both astronauts are veteran Navy test pilots and have previous flights on space shuttles and Russian Soyuz spacecraft. Captains never want to abandon ship, but that’s not what happened with Starliner. Instead, their ship left them.

Williams said she and Wilmore watched Starliner’s departure from the space station from the lab’s multi-window cupola module last week. They kept busy with several tasks, such as monitoring the undocking and managing the space station’s systems during the dynamic phase of the departure.

“We were watching our spaceship fly away at that point in time,” Williams said. “I think it’s good we had some extra activities. Of course, we’re very knowledgeable about Starliner, so it was obvious what was happening at each moment.”

NASA’s top managers did not have enough confidence in Starliner’s safety after five thrusters temporarily failed as the spacecraft approached the space station in June. They weren’t ready to risk the lives of the two astronauts on Starliner when engineers weren’t convinced the same thrusters, or more, would function as needed during the trip home.

It turned out the suspect thrusters on Starliner worked after it departed the space station and headed for reentry on September 6. One thruster on Starliner’s crew module—different in design from the thrusters that previously had trouble—failed on the return journey. Investigating this issue is something Boeing and NASA engineers will add to their to-do list before the next Starliner flight, alongside the earlier problems of overheating thrusters and helium leaks.

“It’s a very risky business, and things do not always turn out the way you want,” Wilmore said. “Every single test flight, especially a first flight of a spacecraft or aircraft that’s ever occurred, has found issues …  90 percent of our training is preparing for the unexpected, and sometimes the actual unexpected goes beyond what you even think that could happen.”

Navy captains don’t like abandoning ship—but with Starliner, the ship left them Read More »

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Leaving behind its crew, Starliner departs space station and returns to Earth

Boeing, commercial crew, Commercial space, human spaceflight, international space station, NASA, Science, Space, starliner / /

It worked —

“We will review the data and determine the next steps for the program,” says Boeing’s Starliner manager.

–

Boeing's Starliner spacecraft after landing Friday night at White Sands Space Harbor, New Mexico.

Enlarge / Boeing’s Starliner spacecraft after landing Friday night at White Sands Space Harbor, New Mexico.

Boeing

Boeing’s Starliner spacecraft sailed to a smooth landing in the New Mexico desert Friday night, an auspicious end to an otherwise disappointing three-month test flight that left the capsule’s two-person crew stuck in orbit until next year.

Cushioned by airbags, the Boeing crew capsule descended under three parachutes toward an on-target landing at 10: 01 pm local time Friday (12: 01 am EDT Saturday) at White Sands Space Harbor, New Mexico. From the outside, the landing appeared just as it would have if the spacecraft brought home NASA astronauts Butch Wilmore and Suni Williams, who became the first people to launch on a Starliner capsule on June 5.

But Starliner’s cockpit was empty as it flew back to Earth Friday night. Last month, NASA managers decided to keep Wilmore and Williams on the International Space Station (ISS) until next year after agency officials determined it was too risky for the astronauts to return to the ground on Boeing’s spaceship. Instead of coming home on Starliner, Wilmore and Williams will fly back to Earth on a SpaceX Dragon spacecraft in February. NASA has incorporated the Starliner duo into the space station’s long-term crew.

The Starliner spacecraft began the journey home by backing away from its docking port at the space station at 6: 04 pm EDT (22: 04 UTC), one day after astronauts closed hatches to prepare for the ship’s departure. The capsule fired thrusters to quickly back away from the complex, setting up for a deorbit burn to guide Starliner on a trajectory toward its landing site. Then, Starliner jettisoned its disposable service module to burn up over the Pacific Ocean, while the crew module, with a vacant cockpit, took aim on New Mexico.

After streaking through the atmosphere over the Pacific Ocean and Mexico, Starliner deployed three main parachutes to slow its descent, then a ring of six airbags inflated around the bottom of the spacecraft to dampen the jolt of touchdown. This was the third time a Starliner capsule has flown in space, and the second time the spacecraft fell short of achieving all of its objectives.

Not the desired outcome

“I’m happy to report Starliner did really well today in the undock, deorbit, and landing sequence,” said Steve Stich, manager of NASA’s commercial crew program, which manages a contract worth up to $4.6 billion for Boeing to develop, test, and fly a series of Starliner crew missions to the ISS.

While officials were pleased with Starliner’s landing, the celebration was tinged with disappointment.

“From a human perspective, all of us feel happy about the successful landing, but then there’s a piece of us that we wish it would have been the way we had planned it,” Stich said. “We had planned to have the mission land with Butch and Suni onboard. I think there are, depending on who you are on the team, different emotions associated with that, and I think it’s going to take a little time to work through that.”

Nevertheless, Stich said NASA made the right call last month when officials decided to complete the Starliner test flight without astronauts in the spacecraft.

“We made the decision to have an uncrewed flight based on what we knew at the time, and based on our knowledge of the thrusters and based on the modeling that we had,” Stich said. “If we’d had a model that would have predicted what we saw tonight perfectly, yeah, it looks like an easy decision to go say, ‘We could have had a crew tonight.’ But we didn’t have that.”

Boeing’s Starliner managers insisted the ship was safe to bring the astronauts home. It might be tempting to conclude the successful landing Friday night vindicated Boeing’s views on the thruster problems. However, he spacecraft’s propulsion system, provided by Aerojet Rocketdyne, clearly did not work as intended during the flight. NASA had the option of bringing Wilmore and Williams back to Earth on a different, flight-proven spacecraft, so they took it.

“It’s awfully hard for the team,” Stich said. “It’s hard for me, when we sit here and have a successful landing, to be in that position. But it was a test flight, and we didn’t have confidence, with certainty, of the thruster performance.”

In this infrared view, Starliner descends under its three main parachutes moments before touchdown at White Sands Space Harbor, New Mexico.

Enlarge / In this infrared view, Starliner descends under its three main parachutes moments before touchdown at White Sands Space Harbor, New Mexico.

NASA

As Starliner approached the space station in June, five of 28 control thrusters on Starliner’s service module failed, forcing Wilmore to take manual control as ground teams sorted out the problem. Eventually, engineers recovered four of the five thrusters, but NASA’s decision makers were unable to convince themselves the same problem wouldn’t reappear, or get worse, when the spacecraft departed the space station and headed for reentry and landing.

Engineers later determined the control jets lost thrust due to overheating, which can cause Teflon seals in valves to swell and deform, starving the thrusters of propellant. Telemetry data beamed back to the mission controllers from Starliner showed higher-than-expected temperatures on two of the service module thrusters during the flight back to Earth Friday night, but they continued working.

Ground teams also detected five small helium leaks on Starliner’s propulsion system soon after its launch in June. NASA and Boeing officials were aware of one of the leaks before the launch, but decided to go ahead with the test flight. Starliner was still leaking helium when the spacecraft undocked from the station Friday, but the leak rate remained within safety tolerances, according to Stich.

A couple of fresh technical problems cropped up as Starliner cruised back to Earth. One of 12 control jets on the crew module failed to ignite at any time during Starliner’s flight home. These are separate thrusters from the small engines that caused trouble earlier in the Starliner mission. There was also a brief glitch in Starliner’s navigation system during reentry.

Where to go from here?

Three NASA managers, including Stich, took questions from reporters in a press conference early Saturday following Starliner’s landing. Two Boeing officials were also supposed to be on the panel, but they canceled at the last minute. Boeing didn’t explain their absence, and the company has not made any officials available to answer questions since NASA chose to end the Starliner test flight without the crew aboard.

“We view the data and the uncertainty that’s there differently than Boeing does,” said Jim Free, NASA’s associate administrator, in an August 24 press conference announcing the agency’s decision on how to end the Starliner test flight. It’s unusual for NASA officials to publicly discuss how their opinions differ from those of their contractors.

Joel Montalbano, NASA’s deputy associate administrator for space operations, said Saturday that Boeing deferred to the agency to discuss the Starliner mission in the post-landing press conference.

Here’s the only quote from a Boeing official on Starliner’s return to Earth. It came in the form of a three-paragraph written statement Boeing emailed to reporters about a half-hour after Starliner’s landing: “I want to recognize the work the Starliner teams did to ensure a successful and safe undocking, deorbit, re-entry and landing,” said Mark Nappi, vice president and program manager of Boeing’s commercial crew program. “We will review the data and determine the next steps for the program.”

Nappi’s statement doesn’t answer one of the most important questions reporters would have asked anyone from Boeing if they participated in Saturday morning’s press conference: Does Boeing still have a long-term commitment to the Starliner program?

So far, the only indications of Boeing’s future plans for Starliner have come from second-hand anecdotes relayed by NASA officials. Boeing has been silent on the matter. The company has reported nearly $1.6 billion in financial charges to pay for previous delays and cost overruns on the Starliner program, and Boeing will again be on the hook to pay to fix the problems Starliner encountered in space over the last three months.

Montalbano said Boeing’s Starliner managers met with ground teams at mission control in Houston following the craft’s landing. “The Boeing managers came into the control room and congratulated the team, talked to the NASA team, so Boeing is committed to continue their work with us,” he said.

Boeing's Starliner spacecraft fires thrusters during departure from the International Space Station on Friday.

Enlarge / Boeing’s Starliner spacecraft fires thrusters during departure from the International Space Station on Friday.

NASA

NASA isn’t ready to give up on Starliner. A fundamental tenet of NASA’s commercial crew program is to foster the development of two independent vehicles to ferry astronauts to and from the International Space Station, and eventually commercial outposts in low-Earth orbit. NASA awarded multibillion-dollar contracts to Boeing and SpaceX in 2014 to complete development of their Starliner and Crew Dragon spaceships.

SpaceX’s Dragon started flying astronauts in 2020. NASA would like to have another US spacecraft for crew rotation flights to support the ISS. If Boeing had more success with this Starliner test flight, NASA expected to formally certify the spacecraft for operational crew flights beginning next year. Once that happens, Starliner will enter a rotation with SpaceX’s Dragon to transport crews to and from the station in six-month increments.

Stich said Saturday that NASA has not determined whether the agency will require Boeing launch another Starliner test flight before certifying the spacecraft for regular crew rotation missions. “It’ll take a little time to determine the path forward, but today we saw the vehicle perform really well,” he said.

On to Starliner-1?

But some of Stich’s other statements Saturday suggested NASA would like to proceed with certifying Starliner and flying the next mission with a full crew complement of four astronauts. NASA calls Boeing’s first operational crew mission Starliner-1. It’s the first of at least three and potentially up to six crew rotation missions on Boeing’s contract.

“It’s great to have the spacecraft back, and we’re now focused on Starliner-1,” Stich said.

Before that happens, NASA and Boeing engineers must resolve the thruster problems and helium leaks that plagued the test flight this summer. Stich said teams are studying several ways to improve the reliability of Starliner’s thrusters, including hardware modifications and procedural changes. This will probably push back the next crew flight of Starliner, whether it’s Starliner-1 or another test flight, until the end of next year or 2026, although NASA officials have not laid out a schedule.

The overheating thrusters are located inside four doghouse-shaped propulsion pods around the perimeter of Starliner’s service module. It turns out the doghouses retain heat like a thermos—something NASA and Boeing didn’t fully appreciate before this mission—and the thrusters don’t have time to cool down when the spacecraft fires its control jets in rapid pulses. It might help if Boeing removes some of the insulating thermal blankets from the doghouses, Stich said.

The easiest method of resolving the problem of Starliner’s overheating thrusters would be to change the rate and duration of thruster firings.

“What we would like to do is try not to change the thruster. I think that is the best path,” Stich said. “There thrusters have shown resilience and have shown that they perform well, as long as we keep their temperatures down and don’t fire them in a manner that causes the temperatures to go up.”

There’s one thing from this summer’s test flight that might, counterintuitively, help NASA certify the Starliner spacecraft to begin operational flights with its next mission. Rather than staying at the space station for eight days, Starliner remained docked at the research lab for three months, half of the duration of a full-up crew rotation flight. Despite the setbacks, Stich estimated the test flight achieved about 85 to 90 percent of its objectives.

“There’s a lot of learning that happens in that three months that is invaluable for an increment mission,” Stich said. “So, in some ways, the mission overachieved some objectives, in terms of being there for extra time. Not having the crew onboard, obviously, there are some things that we lack in terms of Butch and Suni’s test pilot expertise, and how the vehicle performed, what they saw in the cockpit. We won’t have that data, but we still have the wealth of data from the spacecraft itself, so that will go toward the mission objectives and the certification.”

Leaving behind its crew, Starliner departs space station and returns to Earth Read More »

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After another Boeing letdown, NASA isn’t ready to buy more Starliner missions

Boeing, commercial crew, Commercial space, human spaceflight, international space station, NASA, Science, Space, starliner / /
Boeing's Starliner spacecraft sits atop a United Launch Alliance Atlas V rocket before liftoff in June to begin the Crew Flight Test.

Enlarge / Boeing’s Starliner spacecraft sits atop a United Launch Alliance Atlas V rocket before liftoff in June to begin the Crew Flight Test.

NASA is ready for Boeing’s Starliner spacecraft, stricken with thruster problems and helium leaks, to leave the International Space Station as soon as Friday, wrapping up a disappointing test flight that has clouded the long-term future of the Starliner program.

Astronauts Butch Wilmore and Suni Williams, who launched aboard Starliner on June 5, closed the spacecraft’s hatch Thursday in preparation for departure Friday. But it wasn’t what they envisioned when they left Earth on Starliner three months ago. Instead of closing the hatch from a position in Starliner’s cockpit, they latched the front door to the spacecraft from the space station’s side of the docking port.

The Starliner spacecraft is set to undock from the International Space Station at 6: 04 pm EDT (22: 04 UTC) Friday. If all goes according to plan, Starliner will ignite its braking rockets at 11: 17 pm EDT (03: 17 UTC) for a minute-long burn to target a parachute-assisted, airbag-cushioned landing at White Sands Space Harbor, New Mexico, at 12: 03 am EDT (04: 03 UTC) Saturday.

The Starliner mission set to conclude this weekend was the spacecraft’s first test flight with astronauts, running seven years behind Boeing’s original schedule. But due to technical problems with the spacecraft, it won’t come home with the two astronauts who flew it into orbit back in June, leaving some of the test flight’s objectives incomplete.

This outcome is, without question, a setback for NASA and Boeing, which must resolve two major problems in Starliner’s propulsion system—supplied by Aerojet Rocketdyne—before the capsule can fly with people again. NASA officials haven’t said whether they will require Boeing to launch another Starliner test flight before certifying the spacecraft for the first of up to six operational crew missions on Boeing’s contract.

A noncommittal from NASA

For over a decade, the space agency has worked with Boeing and SpaceX to develop two independent vehicles to ferry astronauts to and from the International Space Station (ISS). SpaceX launched its first Dragon spacecraft with astronauts in May 2020, and six months later, NASA cleared SpaceX to begin flying regular six-month space station crew rotation missions.

Officially, NASA has penciled in Starliner’s first operational mission for August 2025. But the agency set that schedule before realizing Boeing and Aerojet Rocketdyne would need to redesign seals and perhaps other elements in Starliner’s propulsion system.

No one knows how long that will take, and NASA hasn’t decided if it will require Boeing to launch another test flight before formally certifying Starliner for operational missions. If Starliner performs flawlessly after undocking and successfully lands this weekend, perhaps NASA engineers can convince themselves Starliner is good to go for crew rotation flights once Boeing resolves the thruster problems and helium leaks.

In any event, the schedule for launching an operational Starliner crew flight in less than a year seems improbable. Aside from the decision on another test flight, the agency also must decide whether it will order any more operational Starliner missions from Boeing. These “post-certification missions” will transport crews of four astronauts between Earth and the ISS, orbiting roughly 260 miles (420 kilometers) above the planet.

NASA has only given Boeing the “Authority To Proceed” for three of its six potential operational Starliner missions. This milestone, known as ATP, is a decision point in contracting lingo where the customer—in this case, NASA—places a firm order for a deliverable. NASA has previously said it awards these task orders about two to three years prior to a mission’s launch.

Josh Finch, a NASA spokesperson, told Ars that the agency hasn’t made any decisions on whether to commit to any more operational Starliner missions from Boeing beyond the three already on the books.

“NASA’s goal remains to certify the Starliner system for crew transportation to the International Space Station,” Finch said in a written response to questions from Ars. “NASA looks forward to its continued work with Boeing to complete certification efforts after Starliner’s uncrewed return. Decisions and timing on issuing future authorizations are on the work ahead.”

This means NASA’s near-term focus is on certifying Starliner so that Boeing can start executing its commercial crew contract. The space agency hasn’t determined when or if it will authorize Boeing to prepare for any Starliner missions beyond the three already on the books.

When it awarded commercial crew contracts to SpaceX and Boeing in 2014, NASA pledged to buy at least two operational crew flights from each company. The initial contracts from a decade ago had options for as many as six crew rotation flights to the ISS after certification.

Since then, NASA has extended SpaceX’s commercial crew contract to cover as many as 14 Dragon missions with astronauts, and SpaceX has already launched eight of them. The main reason for this contract extension was to cover NASA’s needs for crew transportation after delays with Boeing’s Starliner, which was originally supposed to alternate with SpaceX’s Dragon for human flights every six months.

After another Boeing letdown, NASA isn’t ready to buy more Starliner missions Read More »

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NASA wants Starliner to make a quick getaway from the space station

Boeing, commercial crew, Commercial space, human spaceflight, international space station, NASA, Science, Space, starliner / /

WSSHing for success —

Starliner is set to land at White Sands Space Harbor in New Mexico shortly after midnight.

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Boeing's Starliner spacecraft is set to undock from the International Space Station on Friday evening.

Enlarge / Boeing’s Starliner spacecraft is set to undock from the International Space Station on Friday evening.

NASA

Boeing’s Starliner spacecraft will gently back away from the International Space Station Friday evening, then fire its balky thrusters to rapidly depart the vicinity of the orbiting lab and its nine-person crew.

NASA asked Boeing to adjust Starliner’s departure sequence to get away from the space station faster and reduce the workload on the thrusters to reduce the risk of overheating, which caused some of the control jets to drop offline as the spacecraft approached the outpost for docking in June.

The action begins at 6: 04 pm EDT (22: 04 UTC) on Friday, when hooks in the docking mechanism connecting Starliner with the International Space Station (ISS) will open, and springs will nudge the spacecraft away its mooring on the forward end of the massive research complex.

Around 90 seconds later, a set of forward-facing thrusters on Starliner’s service module will fire in a series of 12 pulses over a few minutes to drive the spacecraft farther away from the space station. These maneuvers will send Starliner on a trajectory over the top of the ISS, then behind it until it is time for the spacecraft to perform a deorbit burn at 11: 17 pm EDT (03: 17 UTC) to target landing at White Sands Space Harbor, New Mexico, shortly after midnight EDT (10 pm local time at White Sands).

How to watch, and what to watch for

The two videos embedded below will show NASA TV’s live coverage of the undocking and landing of Starliner.

Starliner is leaving its two-person crew behind on the space station after NASA officials decided last month they did not have enough confidence in the spacecraft’s reaction control system (RCS) thrusters, used to make exact changes to the capsule’s trajectory and orientation in orbit. Five of the 28 RCS thrusters on Starliner’s service module failed during the craft’s rendezvous with the space station three months ago. Subsequent investigations showed overheating could cause Teflon seals in a poppet valve to swell, restricting the flow of propellant to the thrusters.

Engineers recovered four of the five thrusters after they temporarily stopped working, but NASA officials couldn’t be sure the thrusters would not overheat again on the trip home. NASA decided it was too risky for Starliner to come home with astronauts Butch Wilmore and Suni Williams, who launched on Boeing’s crew test flight on June 5, becoming the first people to fly on the commercial capsule. They will remain aboard the station until February, when they will return to Earth on a SpaceX Dragon spacecraft.

The original flight plan, had Wilmore and Williams been aboard Starliner for the trip home, called for the spacecraft to make a gentler departure from the ISS, allowing engineers to fully check out the performance of its navigation sensors and test the craft’s ability to loiter in the vicinity of the station for photographic surveys of its exterior.

“In this case, what we’re doing is the break-out burn, which will be a series of 12 burns, each not very large, about 0.1 meters per second (0.2 mph) and that’s just to take the Starliner away from the station, and then immediately start going up and away, and eventually it’ll curve around to the top and deorbit from above the station a few orbits later,” said Anthony Vareha, NASA’s flight director overseeing ISS operations during Starliner’s undocking sequence.

Astronauts won’t be inside Starliner’s cockpit to take manual control in the event of a major problem, so NASA managers want the spacecraft to get away from the space station as quickly as possible.

On this path, Starliner will exit the so-called approach ellipsoid, a 2.5-by-1.25-by-1.25-mile (4-by-2-by-2-kilometer) invisible boundary around the orbiting laboratory, about 20 to 25 minutes after undocking, NASA officials said. That’s less than half the time Starliner would normally take to leave the vicinity of the ISS.

“It’s a quicker way to get away from the station, with less stress on the thrusters,” said Steve Stich, NASA’s commercial crew program manager. “Essentially, once we open the hooks, the springs will push Starliner away and then we’ll do some really short thruster firings to put us on a trajectory that will take us above the station and behind, we’ll be opening to a nice range to where we can execute the deorbit burn.”

In the unlikely event of a more significant series of thruster failures, the springs that push Starliner away from the station should be enough to ensure there’s no risk of collision, according to Vareha.

“Then, after that, we really are going to just stay in some very benign attitudes and not fire the the thrusters very much at all,” Stich said.

Starliner will need to use the RCS thrusters again to point itself in the proper direction to fire four larger rocket engines for the deorbit burn. Once this burn is complete, the RCS thrusters will reorient the spacecraft to jettison the service module to burn up in the atmosphere. The reusable crew module relies on a separate set of thrusters during reentry.

Finally, the capsule will approach the landing zone in New Mexico from the southwest, flying over the Pacific Ocean and Mexico before deploying three main parachutes and airbags to cushion its landing at White Sands. Boeing and NASA teams there will meet the spacecraft and secure it for a road voyage back to Kennedy Space Center in Florida for refurbishment.

Meanwhile, engineers must resolve the causes of the thruster problems and helium leaks that plagued the Starliner test flight before it can fly astronauts again.

NASA wants Starliner to make a quick getaway from the space station Read More »

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Boeing will try to fly its troubled Starliner capsule back to Earth next week

Boeing, commercial crew, Commercial space, human spaceflight, international space station, NASA, Science, Space, starliner / /

Destination desert —

The two astronauts who launched on Starliner will stay behind on the International Space Station.

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Boeing's Starliner spacecraft undocks from the International Space Station at the conclusion of an unpiloted test flight in May 2022.

Enlarge / Boeing’s Starliner spacecraft undocks from the International Space Station at the conclusion of an unpiloted test flight in May 2022.

NASA

NASA and Boeing are proceeding with final preparations to undock the Starliner spacecraft from the International Space Station next Friday, September 6, to head for landing at White Sands Space Harbor in southern New Mexico.

Astronauts Butch Wilmore and Suni Williams, who were supposed to return to Earth inside Starliner, will remain behind on the space station after NASA decided last week to conclude the Boeing test flight without its crew on board. NASA officials decided it was too risky to put the astronauts on Starliner after the spacecraft suffered thruster failures during its flight to the space station in early June.

Instead, Wilmore and Williams will come home on a SpaceX Dragon capsule no earlier than February, extending their planned stay on the space station from eight days to eight months. Flying on autopilot, the Starliner spacecraft is scheduled to depart the station at approximately 6: 04 pm EDT (22: 04 UTC) on September 6. The capsule will fire its engines to drop out of orbit and target a parachute-assisted landing in New Mexico at 12: 03 am EDT (04: 03 UTC) on September 7, NASA said in a statement Thursday.

NASA officials completed the second part of a two-day Flight Readiness Review on Thursday to clear the Starliner spacecraft for undocking and landing. However, there are strict weather rules for landing a Starliner spacecraft, so NASA and Boeing managers will decide next week whether to proceed with the return next Friday night or wait for better conditions at the White Sands landing zone.

Over the last few days, flight controllers updated parameters in Starliner’s software to handle a fully autonomous return to Earth without inputs from astronauts flying in the cockpit, NASA said. Boeing has flown two unpiloted Starliner test flights using the same type of autonomous reentry and landing operations. This mission, called the Crew Flight Test (CFT), was the first time astronauts launched into orbit inside a Starliner spacecraft, and was expected to pave the way for future operational missions to rotate four-person crews to and from the space station.

With the Starliner spacecraft unable to complete its test flight as intended, there are fundamental questions about the future of Boeing’s commercial crew program. NASA Administrator Bill Nelson said last week that Boeing’s new CEO, Kelly Ortberg, told him the aerospace company remained committed to Starliner. However, Boeing will be on the hook to pay for the cost of resolving problems with overheating thrusters and helium leaks that hamstrung the CFT mission. Boeing hasn’t made any public statements about the long-term future of the Starliner program since NASA decided to pull its astronauts off the spacecraft for its return to Earth.

Preparing for a contingency

NASA is clearly more comfortable with returning Wilmore and Williams to Earth inside SpaceX’s Dragon capsule, but the change disrupts crew operations at the space station. This week, astronauts have been reconfiguring the interior of a Dragon spacecraft currently docked at the outpost to support six crew members in the event of an emergency evacuation.

With Starliner leaving the space station next week, Dragon will become the lifeboat for Wilmore and Williams. If a fire, a collision with space junk, a medical emergency, or something else forces the crew to leave the complex, the Starliner astronauts will ride home on makeshift seats positioned under the four regular seats inside Dragon, where crews typically put cargo during launch and landing.

At least one of the Starliner astronauts would have to come home without a spacesuit to protect them if the cabin of the Dragon spacecraft depressurized on the descent. This has never happened on a Dragon mission before, but astronauts wear SpaceX-made pressure suits to mitigate the risk. The four astronauts who launched on Dragon have their suits, and NASA officials said a spare SpaceX suit already on the space station fit one of the Starliner astronauts, but they didn’t identify which one.

A pressure suit for the other Starliner crew member will launch on the next Dragon spacecraft—on the Crew-9 mission—set for liftoff on a SpaceX Falcon 9 rocket no earlier than September 24. Starliner’s troubles have also disrupted plans for the Crew-9 mission.

On Friday, NASA announced it would remove two astronauts from the Crew-9 mission, including its commander, Zena Cardman, who is a spaceflight rookie. Veteran astronaut Nick Hague will move from the pilot’s seat to take over as Crew-9 commander. Russian cosmonaut Aleksandr Gorbunov will join him.

NASA and Russia’s space agency, Roscosmos, have an agreement to launch Russian cosmonauts on Dragon missions and US astronauts on Russian Soyuz flights to the station. In exchange for NASA providing a ride for Gorbunov, NASA astronaut Don Pettit will fly to the space station on a Soyuz spacecraft next month.

The so-called “seat swap” arrangement ensures that, even if Dragon or Soyuz were grounded, there is always at least one US astronaut and one Russian cosmonaut on the station overseeing each partner’s segment of the outpost, maintaining propulsion, power generating, pointing control, thermal control, and other critical capabilities to keep the lab operational.

Boeing will try to fly its troubled Starliner capsule back to Earth next week Read More »

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NASA’s Starliner decision was the right one, but it’s a crushing blow for Boeing

Boeing, commercial crew, Commercial space, Features, human spaceflight, international space station, NASA, Science, Space, starliner / /

Falling short —

It’s unlikely Boeing can fly all six of its Starliner missions before retirement of the ISS in 2030.

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A Starliner spacecraft mounted on top of an Atlas V rocket before an unpiloted test flight in 2022.

Enlarge / A Starliner spacecraft mounted on top of an Atlas V rocket before an unpiloted test flight in 2022.

Ten years ago next month NASA announced that Boeing, one of the agency’s most experienced contractors, won the lion’s share of government money available to end the agency’s sole reliance on Russia to ferry its astronauts to and from low-Earth orbit.

At the time, Boeing won $4.2 billion from NASA to complete development of the Starliner spacecraft and fly a minimum of two, and potentially up to six, operational crew flights to rotate crews between Earth and the International Space Station (ISS). SpaceX won a $2.6 billion contract for essentially the same scope of work.

A decade later the Starliner program finds itself at a crossroads after Boeing learned it will not complete the spacecraft’s first Crew Flight Test with astronauts onboard. NASA formally decided Saturday that Butch Wilmore and Suni Williams, who launched on the Starliner capsule June 5, will instead return to Earth inside a SpaceX Crew Dragon spacecraft. Put simply, NASA isn’t confident enough in Boeing’s spacecraft after it suffered multiple thrusters failures and helium leaks on the way to the ISS.

So where does this leave Boeing with its multibillion contract? Can the company fulfill the breadth of its commercial crew contract with NASA before the space station’s scheduled retirement in 2030? It now seems that there is little chance of Boeing flying six more Starliner missions without a life extension for the ISS. Tellingly, perhaps, NASA has only placed firm orders with Boeing for three Starliner flights once the agency certifies the spacecraft for operational use.

Boeing’s bottom line

Although Boeing did not make an official statement Saturday on its long-term plans for Starliner, NASA Administrator Bill Nelson told reporters he received assurances from Boeing’s new CEO, Kelly Ortberg, that the company remains committed to the commercial crew program. And it will take a significant commitment from Boeing to see it through. Under the terms of its fixed price contract with NASA, the company is on the hook to pay for any expenses to fix the thruster and helium leak problems and get Starliner flying again.

Boeing has already reported $1.6 billion in charges on its financial statements to pay for delays and cost overruns on the Starliner program. That figure will grow as the company will likely need to redesign some elements in the spacecraft’s propulsion system to remedy the problems encountered on the Crew Flight Test (CFT) mission. NASA has committed $5.1 billion to Boeing for the Starliner program, and the agency has already paid out most of that funding.

Boeing's Starliner spacecraft, seen docked at the International Space Station through the window of a SpaceX Dragon spacecraft.

Enlarge / Boeing’s Starliner spacecraft, seen docked at the International Space Station through the window of a SpaceX Dragon spacecraft.

The next step for Starliner remains unclear, and we’ll assess that in more detail later in the story. Had the Starliner test flight ended as expected, with its crew inside, NASA targeted no earlier than August 2025 for Boeing to launch the first of its six operational crew rotation missions to the space station. In light of Saturday’s decision, there’s a high probability Starliner won’t fly with astronauts again until at least 2026.

Starliner safely delivered astronauts Butch Wilmore and Suni Williams to the space station on June 6, a day after their launch from Cape Canaveral Space Force Station, Florida. But five of the craft’s 28 reaction control system thrusters overheated and failed as it approached the outpost. After the failures on the way to the space station, NASA’s engineers were concerned Starliner might suffer similar problems, or worse, when the control jets fired to guide Starliner on the trip back to Earth.

On Saturday, senior NASA leaders decided it wasn’t worth the risk. The two astronauts, who originally planned for an eight-day stay at the station, will now spend eight months on the orbiting research lab until they come back to Earth with SpaceX.

If it’s not a trust problem, is it a judgement issue?

Boeing managers had previously declared Starliner was safe enough to bring Wilmore and Williams home. Mark Nappi, Boeing’s Starliner program manager, regularly appeared to downplay the seriousness of the thruster issues during press conferences throughout Starliner’s nearly three-month mission.

So why did NASA and Boeing engineers reach different conclusions? “I think we’re looking at the data and we view the data and the uncertainty that’s there differently than Boeing does,” said Jim Free, NASA’s associate administrator, and the agency’s most senior civil servant. “It’s not a matter of trust. It’s our technical expertise and our experience that we have to balance. We balance risk across everything, not just Starliner.”

The people at the top of NASA’s decision-making tree have either flown in space before, or had front-row seats to the calamitous decision NASA made in 2003 to not seek more data on the condition of space shuttle Columbia’s left wing after the impact of a block of foam from the shuttle’s fuel tank during launch. This led to the deaths of seven astronauts, and the destruction of Columbia during reentry over East Texas. A similar normalization of technical problems, and a culture of stifling dissent, led to the loss of space shuttle Challenger in 1986.

“We lost two space shuttles as a result there not being a culture in which information could come forward,” Nelson said Saturday. “We have been very solicitous of all of our employees that if you have some objection, you come forward. Spaceflight is risky, even at its safest, and even at its most routine. And a test flight by nature is neither safe nor routine. So the decision to keep Butch and Suni aboard the International Space Station and bring the Starliner home uncrewed is the result of a commitment to safety.”

Now, it seems that culture may truly have changed. With SpaceX’s Dragon spacecraft available to give Wilmore and Williams a ride home, this ended up being a relatively straightforward decision. Ken Bowersox, head of NASA’s space operations mission directorate, said the managers polled for their opinion all supported bringing the Starliner spacecraft back to Earth without anyone onboard.

However, NASA and Boeing need to answer for how the Starliner program got to this point. The space agency approved the launch of the Starliner CFT mission in June despite knowing the spacecraft had a helium leak in its propulsion system. Those leaks multiplied once Starliner arrived in orbit, and are a serious issue on their own that will require corrective actions before the next flight. Ultimately, the thruster problems superseded the seriousness of the helium leaks, and this is where NASA and Boeing are likely to face the most difficult questions moving forward.

NASA astronauts Butch Wilmore and Suni Williams aboard the International Space Station.

Enlarge / NASA astronauts Butch Wilmore and Suni Williams aboard the International Space Station.

Boeing’s previous Starliner mission, known as Orbital Flight Test-2 (OFT-2), successfully launched in 2022 and docked with the space station, later coming back to Earth for a parachute-assisted landing in New Mexico. The test flight achieved all of its major objectives, setting the stage for the Crew Flight Test mission this year. But the spacecraft suffered thruster problems on that flight, too.

Several of the reaction control system thrusters stopped working as Starliner approached the space station on the OFT-2 mission, and another one failed on the return leg of the mission. Engineers thought they fixed the problem by introducing what was essentially a software fix to adjust timing and tolerance settings on sensors in the propulsion system, supplied by Aerojet Rocketdyne.

That didn’t work. The problem lay elsewhere, as engineers discovered during testing this summer, when Starliner was already in orbit. Thruster firings at White Stands, New Mexico, revealed a small Teflon seal in a valve can bulge when overheated, restricting the flow of oxidizer propellant to the thruster. NASA officials concluded there is a chance, however small, that the thrusters could overheat again as Starliner departs the station and flies back to Earth—or perhaps get worse.

“We are clearly operating this thruster at a higher temperature, at times, than it was designed for,” said Steve Stich, NASA’s commercial crew program manager. “I think that was a factor, that as we started to look at the data a little bit more carefully, we’re operating the thruster outside of where it should be operated at.”

NASA’s Starliner decision was the right one, but it’s a crushing blow for Boeing Read More »

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After months of mulling, NASA will decide on Starliner return this weekend

commercial crew, Commercial space, human spaceflight, international space station, NASA, Science, Space, starliner / /

Standby for news —

“The agency flight readiness review is where any formal dissents are presented and reconciled.”

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A high-resolution commercial Earth-imaging satellite owned by Maxar captured this view of the International Space Station on June 7 with Boeing's Starliner capsule docked at the lab's forward port (lower right).

Enlarge / A high-resolution commercial Earth-imaging satellite owned by Maxar captured this view of the International Space Station on June 7 with Boeing’s Starliner capsule docked at the lab’s forward port (lower right).

Senior NASA leaders, including the agency’s administrator, Bill Nelson, will meet Saturday in Houston to decide whether Boeing’s Starliner spacecraft is safe enough to ferry astronauts Butch Wilmore and Suni Williams back to Earth from the International Space Station.

The Flight Readiness Review (FRR) is expected to conclude with NASA’s most consequential safety decision in nearly a generation. One option is to clear the Starliner spacecraft to undock from the space station in early September with Wilmore and Williams onboard, as their flight plan initially laid out, or to bring the capsule home without its crew.

As of Thursday, the two veteran astronauts have been on the space station for 77 days, nearly 10 times longer than their planned stay of eight days. Wilmore and Williams were the first people to launch and dock at the space station aboard a Starliner spacecraft, but multiple thrusters failed and the capsule leaked helium from its propulsion system as it approached the orbiting complex on June 6.

That led to months of testing—in space and on the ground—data reviews, and modeling for engineers to try to understand the root cause of the thruster problems. Engineers believe the thrusters overheated, causing Teflon seals to bulge and block the flow of propellant to the small control jets, resulting in losing thrust. The condition of the thrusters improved once Starliner docked at the station when they weren’t repeatedly firing, as they need to do when the spacecraft is flying alone.

However, engineers and managers have not yet reached a consensus about whether the same problem could recur, or get worse, during the capsule’s journey back to Earth. In a worst-case scenario, if too many thrusters fail, the spacecraft would be unable to point in the proper direction for a critical braking burn to guide the capsule back into the atmosphere toward landing.

The suspect thrusters are located on Starliner’s service module, which will perform the deorbit burn and then separate from the astronaut-carrying crew module before reentry. A separate set of small engines will fine-tune Starliner’s trajectory during descent.

If NASA managers decide it’s not worth the risk, Wilmore and Williams would extend their stay on the space station until at least February of next year, when they would return to Earth inside a Dragon spacecraft provided by SpaceX, Boeing’s rival in NASA’s commercial crew program. This would eliminate the threat that thruster problems on the Starliner spacecraft might pose to the crew’s safety during the trip to Earth, but it comes with myriad side effects.

These effects include disrupting crew activities on the space station by bumping two astronauts off the next SpaceX flight, exposing Wilmore and Williams to additional radiation during their time in space, and dealing a debilitating blow to Boeing’s Starliner program.

If Boeing’s capsule cannot return to Earth with its two astronauts, NASA may not certify Starliner for operational crew missions without an additional test flight. In that case, Boeing probably wouldn’t be able to complete all six of its planned operational crew missions under a $4.2 billion NASA contract before the International Space Station is due for retirement in 2030.

FRR-eedom to speak

The Flight Readiness Review at NASA’s Johnson Space Center in Houston will begin Saturday morning. Ken Bowersox, a former astronaut and head of NASA’s Space Operations Mission Directorate, will chair the meeting. NASA Administrator Bill Nelson will participate, too. If there’s no unanimous agreement around the table at the FRR, a final decision on what to do could be elevated above Bowersox to NASA’s associate administrator, Jim Free or to Nelson.

“The agency flight readiness review is where any formal dissents are presented and reconciled,” NASA said in a statement Thursday. “Other agency leaders who routinely participate in launch and return readiness reviews for crewed missions include NASA’s administrator, deputy administrator, associate administrator, various agency center directors, the Flight Operations Directorate, and agency technical authorities.”

NASA has scheduled a press conference for no earlier than 1 pm ET (17: 00 UTC) Saturday to announce the agency’s decision and next steps, the agency said.

Lower-level managers will meet Friday in a so-called Program Control Board to discuss their findings and views before the FRR. At a previous Program Control Board meeting, managers disagreed on whether the agency was ready to sign off that the Starliner spacecraft was safe enough to return its astronauts to Earth.

There’s one new piece of information that engineers will brief to the Program Control Board on Friday:

“Engineering teams have been working to evaluate a new model that represents the thruster mechanics and is designed to more accurately predict performance during the return phase of flight,” NASA said. “This data could help teams better understand system redundancy from undock to service module separation. Ongoing efforts to complete the new modeling, characterize spacecraft performance data, refine integrated risk assessments, and determine community recommendations will fold into the agency-level review.”

After months of mulling, NASA will decide on Starliner return this weekend Read More »