Boeing and NASA prepare to bring Starliner home without its crew on Friday

Boeing Starliner docked to ISS

Image Credits: NASA (opens in a new window)

NASA officials expressed confidence that Starliner will have a safe and successful return to Earth late Friday evening, though they had enough reservations about the spacecraft’s performance to conclude that the trip should be undertaken without humans on board. 

The high-stakes mission is now set to officially conclude on Friday, with Starliner making its undocking attempt around 6:04 p.m. EST. Should all go to plan, the spacecraft will land at New Mexico’s White Sands Space Harbor approximately six hours later. 

These final maneuvers will bring to a close a troubled first crewed mission for the Boeing-made Starliner. It was meant to be the final certification mission before the vehicle could enter operation as a regular transporter for astronauts traveling to and from the International Space Station. But technical problems, including issues with several of the spacecraft’s thrusters and a handful of helium leaks in the propulsion systems, cropped up shortly before the vehicle attempted to dock with the station on June 6.

The two astronauts onboard, Butch Wilmore and Suni Williams, ended up boarding the ISS safely. But the issues ultimately extended the mission by several months as NASA and Boeing engineers worked to try to determine the root cause of the anomalies. After weeks of testing, both on the ground using replica hardware and on orbit, NASA ultimately decided on August 24 that Starliner should return to Earth empty, and Wilmore and Williams will come home using a SpaceX capsule in February 2025 instead. 

The return trip will have one major difference from normal return missions from the ISS, which is that Starliner will conduct what’s called a “breakout burn” to quickly move it up and away from the station. This maneuver — which is actually 12 small burns, with an orbital velocity of just 0.1 meter per second each — will see the thrusters pulsing for a shorter period of time than they did during the approach to the station. For this reason, the breakout burn will likely not cause the same problems as engineers observed at the start of the mission, and thus pose no safety threat to the ISS, said Steve Stich, NASA’s commercial crew program manager, during a news conference.

“The reasons we chose doing this breakout burn is it gets the vehicle away from station faster,” he said. “Without the crew on board, able to take manual control if needed, there’s just a lot less variables we need to account for when we do the breakout burn, and it allows us to get the vehicle on the trajectory home that much sooner.”

The next critical maneuver will be the 60-second deorbit burn, which will put Starliner into Earth’s atmosphere and en route to White Sands. The spacecraft will deploy parachutes and airbags to make a soft landing on the ground. 

“We anticipate a good burn, and we have a lot of redundancy, and that’s what we’re relying on to have a safe entry,” he added. 

NASA and Boeing will go through a few months of post-flight analysis of the spacecraft’s performance, but Stich said the teams are already looking at modifications to the system or additional testing to get the vehicle fully certified by the space agency. 

But it’s unclear what the ultimate path will be to certify the spacecraft — let alone how much more it might cost Boeing, which has already incurred costs totaling more than $1.5 billion related to the Starliner program. It’s also unclear whether Boeing would need to perform another crewed test mission. 

If NASA and Boeing’s joint flight control team decides not to perform the undock on Friday, there will be several other opportunities in the coming days. Astronauts onboard the space station have modified the SpaceX Dragon vehicle that’s currently attached to the station with temporary seats in case of an emergency. 

Boeing bleeds another $125M on Starliner program, bringing total losses to $1.6B

Boeing Starliner docked to ISS

Image Credits: NASA (opens in a new window)

Boeing has lost another $125 million on its Starliner astronaut capsule program due to delays in its first crewed flight test, which was supposed to last just eight days — and has now been on orbit for almost two months. 

The aerospace giant has lost $1.6 billion on Starliner, including the $125 million, which was reported to regulators in a quarterly filing. While the company was awarded a massive $4.2 billion contract to accelerate Starliner development in 2014, it was structured as a “fixed-price” model. That means any cost overruns are solely the contractor’s responsibility. 

SpaceX was also awarded a fixed-price contract for astronaut transportation services for $2.6 billion at the same time and has been fulfilling its contracted obligations for the space agency with the Crew Dragon capsule since 2020.

But while SpaceX’s crewed services have soared — to include missions for both NASA and private customers — Boeing has struggled. Under the two contracts, NASA said it would buy six crewed launches each from Boeing and SpaceX, but due to Starliner delays, NASA has purchased an additional eight missions from SpaceX. The Elon Musk-led company is now the only provider of astronaut transportation services for the space agency. 

Serious issues discovered during an uncrewed test flight in 2019 pushed back the date of another test by two years. The company had a moment of brief victory in 2022, when that uncrewed mission was finally successful, but additional problems discovered afterward pushed the crewed flight test to this June. 

That mission, which launched on June 5, delivered NASA astronauts Butch Wilmore and Suni Williams to the ISS. But it didn’t go entirely smoothly; a number of issues, including malfunctioning thrusters, have led Boeing and NASA officials to delay the return of the two astronauts for weeks.

This loss and others has made Boeing executives reticent to take on more fixed-price contracts in the future: “Based on the lessons that we’ve learned in taking on these fixed-price development programs, we have maintained contracting discipline for all future opportunities,” outgoing CEO Dave Calhoun said on an earnings call.

It’s likely that Boeing will incur further losses in the program. NASA has already said it would push back the first Starliner mission to no earlier than August 2025, yet another delay for the program. In an absolute worst-case scenario, major modifications to Starliner’s propulsion system could be very costly.

As of right now, Starliner does not have a return date to Earth. The agency said it was aiming to wrap up a final readiness review in the first week of August and make a decision on the return date at that point. A thruster test conducted on orbit was promising, however, with NASA saying in a July 30 update that the preliminary results showed that the thrusters are back to “preflight levels” of performance. 

TechCrunch Space: The Starliner saga comes to a close — for now

Image Credits: TechCrunch

Hello and welcome back to TechCrunch Space. NASA leadership have made their decision: Starliner will be coming back to Earth — empty. More on that below.

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Story of the week

After months of data analysis and internal deliberation, NASA leadership announced on Saturday that Starliner will be coming back to Earth in September, without a crew. Meanwhile, astronauts Butch Wilmore and Sunita Williams will remain on-board the International Space Station until February 2025, when they will return on SpaceX’s Dragon spacecraft as part of the Crew-9 mission.

“Spaceflight is risky, even at its safest and most routine,” said NASA Administrator Bill Nelson. “A test flight, by nature, is neither safe, nor routine. The decision to keep Butch and Suni aboard the International Space Station and bring Boeing’s Starliner home uncrewed is the result of our commitment to safety: our core value and our North Star.”

NASA astronauts Butch Wilmore and Suni Williams.
Image Credits: Miguel J. Rodriguez Carrillo / AFP / Getty Images

Launchers to come

As the global appetite for orbital launches continues to grow, the competition among new and old space companies to build bigger and better launch vehicles is firing up. ICYMI, here’s my overview of the medium-, heavy- and super-heavy lift rocket landscape, from vehicles that are currently operational to those rockets yet to fly. 

From left: Starship, New Glenn, Neutron, and Terran R.
From left: Starship, New Glenn, Neutron and Terran R.
Image Credits: SpaceX, Blue Origin, Rocket Lab, Relativity

This week in space history

NASA’s probe Voyager 2 made its closest encounter to Saturn on August 26, 1981, at a range of just 63,000 miles. Voyager 2 is such a cool mission: The little probe did flybys of Jupiter, Saturn, Uranus and Neptune, and became the second spacecraft to enter interstellar space, or the space between stars. By the time it concluded observations in the Saturn system on September 28, the spacecraft had transmitted 16,000 images of the planet and the surrounding space.

Saturn
Image Credits: NASA

Boeing bleeds another $125M on Starliner program, bringing total losses to $1.6B

Boeing Starliner docked to ISS

Image Credits: NASA (opens in a new window)

Boeing has lost another $125 million on its Starliner astronaut capsule program due to delays in its first crewed flight test, which was supposed to last just eight days — and has now been on orbit for almost two months. 

The aerospace giant has lost $1.6 billion on Starliner, including the $125 million, which was reported to regulators in a quarterly filing. While the company was awarded a massive, $4.2 billion contract to accelerate Starliner development in 2014, it was structured as a “fixed-price” model. That means any cost overruns are solely the contractor’s responsibility. 

SpaceX was also awarded a fixed-price contract for astronaut transportation services for $2.6 billion at the same time, and has been fulfilling its contracted obligations for the space agency with the Crew Dragon capsule since 2020.

But while SpaceX’s crewed services have soared — to include missions for both NASA and private customers — Boeing has struggled. Under the two contracts, NASA said it would buy six crewed launches each from Boeing and SpaceX, but due to Starliner delays, NASA has purchased an additional eight missions from SpaceX. The Elon Musk-led company is now the only provider of astronaut transportation services for the space agency. 

Serious issues discovered during an uncrewed test flight in 2019 pushed back the date of another test by two years. The company had a moment of brief victory in 2022, when that uncrewed mission was finally successful, but additional problems discovered afterward pushed the crewed flight test to this June. 

That mission, which launched on June 5, delivered NASA astronauts Butch Wilmore and Suni Williams to the ISS. But it didn’t go entirely smoothly; a number of issues, including malfunctioning thrusters, have led Boeing and NASA officials to delay the return of the two astronauts for weeks.

This loss and others has made Boeing executives reticent to take on more fixed-price contracts in the future: “Based on the lessons that we’ve learned in taking on these fixed-price development programs, we have maintained contracting discipline for all future opportunities,” outgoing CEO Dave Calhoun said on an earnings call.

It’s likely that Boeing will incur further losses in the program. NASA has already said it would push back the first Starliner mission to no earlier than August 2025, yet another delay for the program. In an absolute worst-case scenario, major modifications to Starliner’s propulsion system could be very costly.

As of right now, Starliner does not have a return date to Earth. The agency said it was aiming to wrap up a final readiness review in the first week of August and make a decision on the return date at that point. A thruster test conducted on orbit was promising, however, with NASA saying in a July 30 update that the preliminary results showed that the thrusters are back to “preflight levels” of performance.