Boeing’s Starliner spacecraft, designed to be NASA’s second astronaut transport option alongside SpaceX’s Crew Dragon, faces new hurdles after a series of technical failures. The capsule, which carried NASA astronauts Butch Wilmore and Suni Williams to the International Space Station (ISS) last year, was supposed to complete an eight-day test mission. Instead, propulsion system malfunctions extended their stay in space to an unprecedented nine months.
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The astronauts finally returned to Earth this week—but not aboard Starliner. Instead, NASA opted for the reliability of SpaceX’s Dragon capsule, highlighting the severity of the ongoing issues with Boeing’s spacecraft.
Propulsion Problems and Potential Repercussions
Starliner’s propulsion system has been the focal point of its setbacks. The capsule suffered five thruster failures during its approach to the ISS, along with helium leaks that compromised its stability. NASA deemed it unsafe for astronauts to use Starliner for their return journey, instead ordering an uncrewed return mission in September.
These technical problems have cast doubt on Starliner’s future and delayed its certification for routine NASA flights. The space agency is now considering an unprecedented third uncrewed test flight—its fourth overall—before allowing astronauts to board the spacecraft again. “We’re considering various options for Starliner, including the possibility of conducting another uncrewed flight,” said Steve Stich, head of NASA’s Commercial Crew Program. The extra test would focus on validating the spacecraft’s thrusters in space, something that cannot be fully simulated on Earth.
Boeing’s Mounting Challenges
Starliner’s repeated delays and technical failures have come at a steep cost for Boeing. Since 2016, the aerospace giant has absorbed over $2 billion in expenses related to Starliner’s development. Meanwhile, the total value of its NASA contract, initially set at $4.2 billion, has increased by $326 million due to continued modifications and delays.
Boeing is now planning a ground test this summer to assess the propulsion system and address the helium leaks. NASA and Boeing engineers believe the thruster failures stem from overheating, which causes Teflon seals in the system to bulge, restricting propellant flow. Adjustments to the design and operational procedures are being explored, but there is no clear timeline for the spacecraft’s return to service.
Competition with SpaceX
Boeing’s delays have given SpaceX an even stronger foothold in the commercial spaceflight market. SpaceX’s Crew Dragon has successfully flown 11 astronaut missions for NASA since its crewed test flight in 2020, making it the dominant provider of human space transport for the agency.
Starliner was supposed to provide a crucial backup to Crew Dragon, ensuring redundancy for NASA’s missions to low-Earth orbit. However, with ongoing uncertainties surrounding Starliner’s next steps, SpaceX continues to expand its lead. The company recently completed its ninth long-duration astronaut mission to the ISS (Crew-9) and is already planning additional crewed flights, possibly outpacing Boeing even further.
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Despite its setbacks, Boeing is still positioning Starliner for a future beyond NASA missions. The company envisions the spacecraft playing a role in transporting astronauts to privately developed space stations, which are in early stages of development. However, before those ambitions can be realized, Boeing must first prove that Starliner is a safe and reliable transport option. NASA has yet to make a final decision on whether Starliner’s next mission will be crewed or uncrewed, but the agency remains cautious. “We need to make sure we can eliminate the helium leaks and the service module thruster issues,” Stich emphasized.