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Boeing Starliner
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Boeing Starliner Spacecraft 2 approaching the ISS in May 2022, during Orbital Flight Test 2 | |
| Manufacturer | Boeing Defense, Space & Security |
|---|---|
| Country of origin | United States |
| Operator | Boeing Defense, Space & Security |
| Applications | ISS crew transport |
| Website | boeing |
| Specifications | |
| Spacecraft type | Capsule |
| Payload capacity | To ISS: 4 crew and 100 kg (220 lb) cargo[3][a] |
| Crew capacity | Up to 7 |
| Volume | 11 m3 (390 cu ft)[5] |
| Regime | Low Earth orbit |
| Design life | |
| Dimensions | |
| Length | 5.03 m (16.5 ft) (Capsule and SM)[6] |
| Diameter | 4.56 m (15 ft)[6] |
| Production | |
| Status | Active |
| Built | 3 |
| Operational | 2 |
| Retired | 1 |
| Maiden launch | Uncrewed: December 20, 2019 Crewed: June 5, 2024 |
| Related spacecraft | |
| Launch vehicle | Atlas V N22[b] |
| Configuration | |
Exploded view of the Starliner A: Crew capsule, B: Service module 1: Nosecone, 2: Parachute compartment cover, 3: Crew access hatch, 4: RCS thrusters for re-entry, 5: Airbags, 6: Heat shield, 7: NASA Docking System, 8: Parachutes, 9: Window, 10: Umbilical, 11: Radiators, 12: "Doghouse" with RCS and OMAC thrusters, 13: Propellant tanks, 14: Roll control thruster, 15: RS-88 engines for launch escape, 16: Solar panels | |
The Boeing Starliner (or CST-100)[c] is a spacecraft designed to transport crew to and from the International Space Station (ISS) and other low-Earth-orbit destinations. Developed by Boeing under NASA's Commercial Crew Program (CCP), it consists of a reusable crew capsule and an expendable service module.
Slightly larger than the Apollo command module or SpaceX Crew Dragon, but smaller than the Orion capsule, the Starliner can accommodate a crew of up to seven, though NASA plans to fly no more than four. It can remain docked to the ISS for up to seven months and is launched on an Atlas V N22 rocket from Cape Canaveral Space Launch Complex 41 in Florida.
In 2014, NASA awarded Boeing a US$4.2 billion fixed-price contract to develop and operate Starliner, while SpaceX received $2.6 billion to develop and operate Crew Dragon. By February 2025, Boeing's effort had exceeded its budget by at least $2 billion.
Originally planned to be operational in 2017, Starliner has been repeatedly delayed by problems in management and engineering. The first uncrewed Orbital Flight Test in December 2019 was deemed a partial failure, leading to a second Orbital Flight Test in May 2022. During the Crew Flight Test, launched in June 2024, the Starliner's thrusters malfunctioned on approach to the ISS, and NASA concluded that it was too risky to return its astronauts to Earth aboard the spacecraft, so it returned uncrewed in September 2024.
Background
[edit]
As the Space Shuttle program drew to a close, NASA sought to foster the development of new spaceflight capabilities. Departing from the traditional model of government-owned and operated spacecraft, NASA proposed a different approach: companies would own and operate spacecraft while NASA would act as a customer, purchasing flights as needed. NASA offered funding to support the development of these new vehicles, but unlike previous cost-plus contracts these new contracts would be fixed-price, placing the financial risk of cost overruns on the companies themselves.
Boeing had an extensive history of developing vehicles for space exploration, having built the first stage (S-IC) of the Saturn V rockets, assembling the Lunar Roving Vehicles, and serving as the prime contractor for the US Orbital Segment of the ISS since 1993. With this record and deep expertise, Boeing was seen as well-positioned to compete for the commercial spaceflight contracts.[7][8]
In 2010, Boeing unveiled its entry into NASA's Commercial Crew Program competition: the CST-100. The company received initial funding of $18 million in the first round of the Commercial Crew Development (CCDev 1) program to support Starliner's development.[9] Additionally, United Launch Alliance, a joint venture between Boeing and Lockheed Martin, secured $6.7 million to develop the Emergency Detection System to allow its Atlas V rocket to be human-rated to launch Starliner.[9] At the time, Boeing expressed optimism that the Starliner could be operational as early as 2015, contingent upon timely approvals and funding.[10]
In October 2011, NASA announced that the Orbiter Processing Facility-3 at Kennedy Space Center would be leased to Boeing for manufacture and test of Starliner, through a partnership with Space Florida.[11]
Over the next three years, NASA held three more rounds of development funding, awarding Boeing $92.3 million under CCDev 2 in 2011,[12] $460 million under the Commercial Crew integrated Capability (CCiCap) program in 2012,[13] and $9.9 million under the Certification Products Contract (CPC) in 2013.[14]
NASA was expected to announce its selection for the lucrative Commercial Crew Transportation Capability (CCtCap) contract in September 2014. Boeing had lobbied NASA for a sole-source contract, arguing that it needed the program's full budget for the successful development of Starliner. Within NASA, there was considerable support for this approach, with many decision-makers expressing confidence in Boeing's capabilities and safety record. In fact, NASA officials had even drafted a justification for selecting Boeing as the sole provider.[15]
While William H. Gerstenmaier, NASA's human exploration lead, had considered the Starliner proposal as stronger,[16] he was hesitant to award a sole-source contract. The multi-year Commercial Crew Program had been designed to foster competition and redundancy, and Gerstenmaier believed that selecting just one company would undermine these goals.[17] Through his efforts, he successfully convinced NASA to delay the CCtCap announcement and secure additional funding to support two competing efforts.[15]
On September 16, 2014, NASA announced that both Boeing and SpaceX would be awarded CCtCap contracts to develop crewed spacecraft. Boeing received a US$4.2 billion to complete and certify the Starliner, while SpaceX received a US$2.6 billion to complete and certify Crew Dragon.[17] To receive the full contract amount, each company would need to successfully complete an abort test, an uncrewed orbital flight test, a crewed orbital flight test, and six crewed missions to the ISS. However, NASA would not need to pay for any failed tests and was only required to purchase two crewed missions to the ISS from each company.[18] Following the initial guaranteed missions, the companies would compete for launch contracts on an ongoing basis.
In November 2015, NASA announced that it had dropped Boeing from consideration in the separate multibillion-dollar Commercial Resupply Services competition to fly cargo to the International Space Station.[19]
Development
[edit]


The name CST-100 was first used when the capsule was unveiled to the public in June 2010.[20] The acronym "CST" stands for Crew Space Transportation, while the number "100" represents to the Kármán line, the unofficial boundary of space located at an altitude of 100 kilometers (62 mi) above Earth.[21] The design draws upon Boeing's experience with NASA's Apollo, Space Shuttle, and ISS programs, as well as the Orbital Express project.[10]

The spacecraft consists of a reusable capsule and an expendable service module and is designed for missions to low Earth orbit. The capsule accommodates seven passengers, or a mix of crew and cargo. For NASA missions to the ISS it will carry four passengers and a small amount of cargo. The Starliner capsule uses a weldless, spun-formed structure and is reusable up to ten times with a six-month turnaround time. Boeing plans to alternate between two reusable crew modules for all planned Starliner missions. Each flight uses a new service module, which provides propulsion and power-generation capacity for the spacecraft. Starliner features wireless Internet and tablet technology for crew interfaces.[22]
Starliner uses the NASA Docking System.[23][24][25] Boeing modified the Starliner design prior to OFT-2, adding a hinged re-entry cover below its expendable nosecone for additional protection of the docking port during atmospheric entry. This was tested on the OFT-2 mission. By contrast, the reusable SpaceX Dragon 2 nosecone is hinged and protects its docking port during both launch and reentry.[26][27][28]
The capsule uses the Boeing Lightweight Ablator for its re-entry heat shield.[29]
Solar cells provided by Boeing subsidiary Spectrolab are installed onto the aft face of the service module, providing 2.9 kW of electricity.[30]
In addition to the capsule and service module, a 5.8 ft (1.78 m) structure called an aeroskirt is integrated into the launch vehicle adapter of Atlas V. The aeroskirt provides aerodynamic stability and dampens the shock waves that come from the front of the rocket.[31]
The spacecraft's propulsion system is produced by Aerojet Rocketdyne and consists of 64 engines:
- 12 × 100 lbf (440 N) MR-104J RCS (reaction control system) thrusters on the capsule, using hydrazine monopropellant and reserved for orienting the capsule during atmospheric re-entry[32]
- 52 on the service module using monomethylhydrazine and nitrogen tetroxide bipropellant:
- 28 × 85 lbf (380 N) RCS thrusters on the service module for attitude control during the majority of the flight
- 20 × 1,500 lbf (6,700 N) OMAC (orbital maneuvering and attitude control) thrusters for altering orbits
- 4 × 40,000 lbf (180,000 N) RS-88 engines for launch escape capability in the event of an abort[33]
The RCS and OMAC thrusters on the service module are grouped into four "doghouses" equally spaced around the perimeter of the service module, each containing five OMAC thrusters (three aft-facing and two forward-facing[disputed – discuss]), and seven RCS thrusters:[34][35] two aft-facing, two forward-facing, and one each in the radial and two tangential directions. The latter three are in a plane which is very close to the spacecraft's center of mass.
To translate the spacecraft, thrusters are used in balanced pairs so that the center of force goes through the spacecraft's center of mass. To rotate the spacecraft, thrusters are used in unbalanced pairs so there is no net force and the net torque is centered within the spacecraft. The RCS thrusters are used for rotation (attitude control) and very fine docking maneuvers, while the OMAC thrusters are used for significant orbital adjustments. The RCS thrusters are also used to compensate for slight imbalances in the OMAC thrusters.
Boeing designed the capsule to make ground landings instead of a splashdown, a first for a crewed capsule mission launched from the United States. After reentering the atmosphere, three parachutes are deployed, slowing the capsule to approximately 4 miles per hour (350 ft/min; 1.8 m/s). Before reaching the ground, six airbags deploy to cushion the landing. There are four primary landing locations, including two sites inside the White Sands Missile Range in New Mexico, the Willcox Playa in Arizona and the Dugway Proving Ground in Utah. Edwards Air Force Base in California serves as a contingency landing location.[36] All of the landing sites are in the Western United States, allowing the service module to be jettisoned for a destructive reentry over the Pacific Ocean. Boeing says that between all five landing sites, there are around 450 landing opportunities each year.[37]
Following the award of the Commercial Crew Transportation Capability (CCtCap) contract in 2014, NASA assigned a team of four experienced astronauts, Bob Behnken, Eric Boe, Doug Hurley, and Sunita Williams, to serve as consultants to engineers at both Boeing and SpaceX.[38] These astronauts were also slated to be the test pilots on the inaugural missions. Hurley recounted a stark contrast in the working relationships between the astronauts and the engineers at the two companies. While the SpaceX engineers were receptive to feedback, enthusiastic about collaborating, and attentive to suggestions, Hurley found the Boeing engineers to be indifferent, arrogant, and overconfident. He also said the Boeing team failed to inform the astronauts about the propellant leak that occurred during the Pad Abort Test. Ultimately, Hurley told the chief of the astronaut office that he would not fly on Starliner. Hurley and Behnken later went on to command the Crew Dragon's historic Demo-2 mission, the first crewed flight of the spacecraft.[39] Williams flew into space on the Boeing Crew Flight Test, but returned to Earth on a Crew Dragon, after thrusters malfunctioned on the Starliner.
Despite being initially awarded significantly more funding, Boeing faced substantial internal budget overruns for the Starliner program, exceeding $2 billion as of February 2025[update].[40]
In November 2019, NASA's Office of Inspector General released a report revealing that a change to Boeing's contract had occurred in 2016,[41] stating: "For Boeing's third through sixth crewed missions, we found that NASA agreed to pay an additional $287.2 million above Boeing's fixed prices to mitigate a perceived 18-month gap in ISS flights anticipated in 2019 and to ensure the contractor continued as a second commercial crew provider", and NASA and Boeing committed to six missions instead of the last four being optional.[42]
Post Crew Flight Test
[edit]In August 2024, after the setbacks experienced during the Crew Flight Test, NASA Administrator Bill Nelson stated that Boeing CEO Kelly Ortberg committed to continuing the Starliner program.[43] However, financial analysts expressed skepticism that Boeing would continue to invest in a money-losing program,[44] and in October The Wall Street Journal reported that Boeing was exploring a sale of some of its space division programs, including Starliner.[45] But in March 2025, Commercial Crew Program manager Steve Stich stated that the next flight may happen in late 2025 or early 2026.[46]
On July 10, 2025, Stich stated that the next Starliner flight would likely be an unmanned cargo mission. Stich also elaborated on the main issues that Starliner was facing in its development, namely the oxidizer valves, more specifically, how the temperature controls required for effective pulses of fuel and oxidizer through these valves are not at a consistent level NASA deems acceptable. Stich stated that these valves were not designed to be opened and closed when the Starliner's RCS thrusters were also operating, as the RCS thrusters impacted the temperature in the valves and thus their ability to open and close. Stich stated that steady progress was being made, and concluded by saying NASA was optimistic that another manned Starliner flight would take place for the second slot in the crew program in the later part of 2026.[47]
Testing
[edit]Various validation tests began on test articles in 2011 and continued on actual spacecraft starting in 2019.
Abort and drop tests
[edit]

In September 2011, Boeing announced the completion of a set of ground drop tests to validate the design of the airbag cushioning system. The airbags are located underneath the heat shield of the Starliner, which is designed to be separated from the capsule while under parachute descent at about 5,000 ft (1,500 m) altitude. The airbags, manufactured by ILC Dover, are deployed by filling with a mixture of compressed nitrogen and oxygen gas, not with the pyro-explosive mixture sometimes used in automotive airbags. The tests were carried out in the Mojave Desert of southeast California, at ground speeds between 10 and 30 mph (16 and 48 km/h) in order to simulate crosswind conditions at the time of landing. Bigelow Aerospace built the mobile test rig and conducted the tests.[48]
In April 2012, Boeing dropped a mock-up of its Starliner over the Nevada desert at the Delamar Dry Lake, Nevada, successfully testing the craft's three main landing parachutes from 11,200 ft (3,400 m).[49]
Boeing reported in May 2016 that its test schedule would slip by eight months in order to reduce the mass of the spacecraft, address aerodynamics issues anticipated during launch and ascent on the Atlas V rocket, and meet new NASA-imposed software requirements.[50] The Orbital Flight Test was scheduled for spring 2019. The booster for this Orbital Flight Test, an Atlas V N22 rocket, was assembled at United Launch Alliance's (ULA) facility at Decatur, Alabama by the end of 2017.[51] The first crewed flight (Boe-CFT) was scheduled for summer 2019, pending test results from Boe-OFT. It was planned to last 14 days and carry one NASA astronaut and one Boeing test pilot to the ISS.[52] On April 5, 2018, NASA announced that the first planned two-person flight, originally slated for November 2018, was likely to occur in 2019 or 2020.[53]
A serious incident occurred during a hot-fire test in June 2018. A design flaw in the propellant system left four of eight valves open, leading to the release of over 4,000 pounds (1,800 kg) of toxic monomethylhydrazine propellant, resulting in a fireball that engulfed the equipment. The incident was reportedly exacerbated by animosity with the propulsion system subcontractor, Aerojet Rocketdyne, who Boeing refused to pay for design changes. While it informed NASA of the incident, Boeing attempted to keep the incident quiet, even withholding information from the astronauts involved in the project.[54]
In October 2018, the first unpiloted orbital mission was delayed to April 2019, and the first crew launch was rescheduled to August 2019.[55][56] In March 2019, Reuters reported that these test flights had been delayed by at least three months,[57] and in April 2019 Boeing announced that the unpiloted orbital mission was scheduled for August 2019.[58]

In May 2019, all major hot-fire testing, including simulations of low-altitude abort-thruster testing, was completed using a full up-to-service module test article that was "flight-like," meaning that the service module test rig used in the hot-fire testing included fuel and helium tanks, reaction control system, orbital maneuvering, and attitude-control thrusters, launch abort engines and all necessary fuel lines and avionics that will be used for crewed missions. This cleared the way for the pad abort test and the subsequent uncrewed and crewed flights.[59]
A pad abort test took place on November 4, 2019.[60] The capsule accelerated away from its pad, but then one of the three parachutes failed to deploy, and the capsule landed with only two parachutes.[61][62] Landing was, however, deemed safe, and the test a success. Boeing did not expect the malfunction of one parachute to affect the Starliner development schedule.[63]
First orbital flight test (uncrewed)
[edit]

The uncrewed Boeing Orbital Flight Test (OFT) launched on December 20, 2019, bearing an Anthropomorphic Test Device nicknamed "Rosie the Rocketeer" and clothed in Boeing's blue IVA spacesuit[64] as well as a Plush toy of Jedediah Kerman from Kerbal Space Program.[65] It landed two days later, having nearly ended in catastrophic failure. The mission was ultimately declared a partial failure.[54]
After launch, the spacecraft captured a "mission elapsed time" from its Atlas V launch vehicle that was 11 hours off. Consequently, when the spacecraft separated from the rocket, instead of briefly firing its reaction control thrusters to enter orbit, its computers commanded them to fire for far longer, consuming so much fuel that the spacecraft no longer had enough to dock with the ISS.[54][66][67] As the capsule was prepared for re-entry, another software error was discovered; it could have caused a catastrophic collision between the service module and crew capsule.[54][68]
The spacecraft landed at White Sands Missile Range, New Mexico, two days after launch.[69] After its landing, NASA astronaut Sunita Williams named the spacecraft Calypso after the research vessel RV Calypso used by oceanographic researcher Jacques Cousteau.[70]
After the mission, Boeing vice president John Mulholland acknowledged that the company had not conducted integrated end-to-end tests for the entire mission, but had instead performed tests of smaller segments. This approach contributed to the software errors that led to the near-catastrophic failures during the flight test. Mulholland insisted that Boeing cut no corners, and that end-to-end tests were not omitted to save money. NASA was also faulted for not pressing Boeing to conduct an end-to-end test.[54]
The subsequent NASA–Boeing investigation into the flight made scores of recommendations for Boeing and NASA. Boeing declared these to be proprietary, so the only ones publicly known are the ones that officials deliberately disclosed. In 2020, company officials said they were addressing 80 of the recommendations.[71]
Second orbital flight test (uncrewed)
[edit]
Because the first OFT did not achieve its objectives, Boeing officials said on April 6, 2020 that the Starliner crew capsule would fly a second uncrewed demonstration mission, Boeing Orbital Flight Test 2 (OFT-2), before flying astronauts. NASA said that it had accepted a recommendation from Boeing to fly a second unpiloted mission. The Washington Post reported that the second orbital flight test, with much the same objectives as the first, was expected to launch from Cape Canaveral "sometime in October or November 2020". Boeing said that it would fund the unplanned crew capsule test flight "at no cost to the taxpayer". Boeing told investors earlier in 2020 that it was taking a US$410 million charge against its earnings to cover the expected costs of a second unpiloted test flight.[72] Boeing officials said on August 25, 2020 that they set the stage for the first Starliner demonstration mission with astronauts in mid-2021.[26] Boeing modified the design of the Starliner docking system prior to OFT-2 to add a re-entry cover for additional protection during the capsule's fiery descent through the atmosphere. This re-entry cover is hinged, like the SpaceX design. Teams also installed the OFT-2 spacecraft's propellant heater, thermal-protection tiles, and the airbags used to cushion the capsule's landing. The crew module for the OFT-2 mission began acceptance testing in August 2020, which is designed to validate the spacecraft's systems before it is mated with its service module, according to NASA.[26][27][28] On November 10, 2020, NASA's Commercial Crew Program manager Steve Stich said that the second orbital flight test would be delayed until first quarter 2021 due to software issues.[73] The uncrewed test continued to slip, with the OFT-2 uncrewed test flight being scheduled for March 2021 and the crewed flight targeted for a launch the following summer.[74] The launch date of OFT-2 moved again with the earliest estimated launch date set for August 2021.[75]
During the August 2021 launch window some issues were detected with 13 propulsion-system valves in the spacecraft prior to launch. The spacecraft had already been mated to its launch rocket, United Launch Alliance's (ULA) Atlas V, and taken to the launchpad. Attempts to fix the problem while on the launchpad failed, and the rocket was returned to the ULA's VIF (Vertical Integration Facility). Attempts to fix the problem at the VIF also failed, and Boeing decided to return the spacecraft to the factory, thus cancelling the launch at that launch window.[76][77] There was a commercial dispute between Boeing and Aerojet Rocketdyne over responsibility for fixing the problem.[78] The valves had been corroded by intrusion of moisture, which interacted with the propellant, but the source of the moisture was not apparent. By late September 2021, Boeing had not determined the root cause of the problem, and the flight was delayed indefinitely.[79] Through October 2021, NASA and Boeing continued to make progress and were "working toward launch opportunities in the first half of 2022",[80] In December 2021, Boeing decided to replace the entire service module and anticipated OFT-2 to occur in May 2022.[81][82]
The OFT-2 mission launched on May 19, 2022.[83] It again carried Rosie the Rocketeer test dummy suited in the blue Boeing inflight spacesuit.[84][85] Two Orbital Maneuvering and Attitude Control (OMAC) thrusters failed during the orbital insertion burn, but the spacecraft was able to compensate using the remaining OMAC thrusters with the addition of the Reaction Control System (RCS) thrusters. A couple of RCS thrusters used to maneuver Starliner also failed during docking due to low chamber pressure. Some thermal systems used to cool the spacecraft showed extra cold temperatures, requiring engineers to manage it during the docking.[86][87]
On May 22, 2022, the capsule docked with the International Space Station.[88] On May 25, 2022, the capsule returned from space and landed successfully.[89] During reentry one of the navigation systems dropped communication with the GPS satellites, but Steve Stich, program manager for NASA's Commercial Crew Program, said this is not unexpected during reentry.[90]
Third orbital flight test (crewed)
[edit]

Starliner's crewed flight test was intended to be the capsule's final evaluation before entering regular NASA service. The plan was to launch two astronauts (commander Barry Wilmore and pilot Sunita Williams), dock with the ISS for about a week, and return to Earth roughly eight days later.[91] But on approach to the ISS, the spacecraft began losing several of its eight aft-facing reaction control system (RCS) thrusters. After two failed, commander Wilmore took manual control, noting the vehicle was more sluggish than during a test the day before. NASA waived standard flight rules to allow docking despite the degraded conditions. Eventually four thrusters failed, resulting in a loss of six degrees of freedom (6DOF) attitude control.[92][93] The astronauts later described the situation as "very precarious."[92]
Wilmore could no longer fully control the capsule, but abandoning the docking attempt was not a safe option either, as the same thrusters were needed to orient Starliner for its deorbit burn and reentry. The team at NASA Mission Control (which Boeing contracted to operate the spacecraft) decided to attempt a reset—essentially a thruster reboot. Wilmore stabilized the capsule before calling down, "Hands off," allowing Mission Control to override the flight software and reactivate the failed jets. Two thrusters came back online, but shortly after, a fifth thruster failed. A second reset restored all but one thruster, allowing Starliner to complete its planned autonomous docking.[92][94] During the flight, five helium leaks were also detected in the service module.[95]
Despite NASA and Boeing's public reassurances, Wilmore and Williams later said that on June 6 when they docked they already privately doubted Starliner's ability to return them safely to Earth.[92] Boeing, however, continued to express confidence in the capsule's design.[96][97] NASA and Boeing continued to assess the situation, and by late August NASA had concluded that the risks of returning with crew were too high.[98] The spacecraft returned uncrewed and landed safely at White Sands Missile Range on 7 September at 04:01:35 UTC (6 September, 11:01:35 pm MDT, local time at the landing site), about six hours after it undocked from the ISS.[99][100]
The mission, originally scheduled for 2017,[101] had already been plagued by delays due to parachute system issues and wiring concerns.[102][103] A launch attempt on May 6, 2024, was scrubbed due to an oxygen valve problem on the rocket.[104] Subsequently, a helium leak in the service module further delayed the mission.[105][106] Another attempt on June 1 was scrubbed due to a ground computer hardware fault.[107] Starliner launched on June 5 at 14:52 UTC (10:52 am EDT).[108]
A ground investigation later linked the thruster degradation to a Teflon seal warped by heat.[109] While the on-orbit issues were replicated in tests at White Sands using hardware planned for future flights, they could not be reproduced aboard the in-flight Starliner.[96][110] During reentry, Starliner experienced a brief navigation glitch and the failure of an orientation thruster, issues unrelated to the earlier problems.[111] NASA has committed to a full review of mission data to determine what further steps are needed for certification.[112] NASA administrator Bill Nelson stated that Boeing CEO Kelly Ortberg committed to continuing the Starliner program despite the setbacks.[43] Boeing, however, drew criticism after abruptly canceling its participation in a post-landing press conference and refusing to answer questions from journalists, opting to release only brief written statements.[111]
Commercial use
[edit]
Under the CCP, Boeing owns and operates the Starliner capsules, allowing the company to offer non-CCP commercial flights if they do not interfere with NASA missions.[113] While SpaceX has secured private commercial flights, Boeing has yet to do so.
The CCP agreement permits Boeing to sell seats for space tourists on ISS flights. While initially proposed, the extended length of typical ISS missions makes this unlikely.[114]
In October 2021, Blue Origin, Boeing, and Sierra Nevada Corporation announced plans for a commercial space station called Orbital Reef. This "mixed-use business park" could be serviced by both Starliner and Sierra Nevada's Dream Chaser spacecraft.[115][116][117]
Launch vehicle
[edit]Starliner was designed to be compatible with multiple launch vehicles, including the Atlas V, Delta IV, Falcon 9, and Vulcan Centaur.[118]
For the three completed test flights and up to six further missions, Starliner is expected to fly atop the Atlas V. However, United Launch Alliance, the operator of the Atlas V, ceased production of the rocket in 2024 after producing vehicles for all remaining contracted launches.[119][120] The vehicles have been allocated to customers, including the six needed for the remaining Starliner flights.[121]
The Starliner faces an uncertain future after that. Delta IV is retired and no more are available,[122] the Falcon 9 is owned by crewed launch competitor SpaceX, and the Vulcan Centaur has not yet been human-rated, testing Boeing would have to pay for.[121]
Configuration
[edit]For Starliner launches, ULA uses the Atlas N22 configuration. All other Atlas V launches use a payload fairing and the single-engine version of the Centaur upper stage. N22 is configured with no payload fairing, two solid rocket boosters (SRBs), and a Dual Engine Centaur second stage. Starliner is the only crewed payload for Atlas V.
While most Atlas V launches since 2021 have used the newer Northrop Grumman GEM63 SRBs, these boosters are not rated for human spaceflight. Therefore, crewed missions employ the older Aerojet Rocketdyne AJ-60A SRBs.[123]
Although the Dual Engine Centaur had not been used since 2000 after the introduction of the more powerful Atlas V, it was brought back into service for Starliner missions. Two engines allow the rocket to fly a gentler and flatter trajectory to minimize the G-forces experienced by the astronauts and ensures the capsule can abort at any time, returning the crew to Earth in case of a problem.[124][125]
Launch profile
[edit]After passing through the stages of max q, SRB jettison, booster separation, Centaur ignition, nosecone and aeroskirt jettison, it releases the Starliner spacecraft at stage separation, nearly 15 minutes after lift-off on a 112 mi × 45 mi-high (181 km × 72 km) suborbital trajectory, just below the orbital velocity needed to enter a stable orbit around Earth. After separating from the Dual Engine Centaur, the Starliner's own thrusters, mounted on its service module, boost the spacecraft into orbit to continue its journey to the International Space Station.
The suborbital trajectory is unusual for a satellite launch, but it is similar to the technique used by the Space Shuttle and Space Launch System. It ensures that, if the spacecraft fails to make the orbital insertion burn, it will re-enter the atmosphere in a controlled way.[126] The Starliner's orbit insertion burn begins about 31 minutes into the mission and lasts 45 seconds.[127]
List of spacecraft
[edit]As of January 2020[update], Boeing planned to have three Boeing Starliner capsules in service to fulfill the needs of the Commercial Crew Program with each capsule expected to be capable of being reused up to ten times with a six-month refurbishment time.[128][129] On August 25, 2020, Boeing announced it would alternate between just two capsules for all planned Starliner missions instead of three.[26]
| S/N | Name | Type | Status | Flights | Flight time | Total flight time | Notes[130][131] | Cat. |
|---|---|---|---|---|---|---|---|---|
| S1 | None | Prototype | Retired | 1 | 1m 19s (PAT) | 1m 19s | Prototype used only for pad abort test. | |
| S2 | TBA | Crew | Active | 1 | 5d 23h 54m (OFT-2) | 5d 23h 54m | Completed the OFT-2 flight. | |
| S3 | Calypso | Crew | Active | 2 | 95d 14h 31m | Named after Jacques Cousteau's ship RV Calypso. First Starliner to orbit during OFT, first to carry crew to space during CFT. |
List of flights
[edit]List includes only completed or currently manifested missions. Dates are listed in UTC, and for future events, they are the earliest possible opportunities (also known as NET dates) and may change.
| Mission and Patch | Capsule | Launch date | Landing date | Remarks | Crew | Outcome |
|---|---|---|---|---|---|---|
| Pad Abort Test (patch) |
S1 | November 4, 2019 | Simulating an escape from a failing rocket, Starliner's RS-88 engines lifted the capsule from a pad at White Sands. Only two of three parachutes opened, but was declared a success. | — | Success | |
| Orbital Flight Test (patch) |
S3.1 Calypso |
December 19, 2019 | December 22, 2019 | First uncrewed orbital flight test. Orbited but failed to rendezvous with ISS. Landed successfully. | — | Partial failure |
| Orbital Flight Test 2 (patch) |
S2.1 | May 19, 2022 | May 25, 2022 | Second uncrewed orbital flight test. Experienced OMAC and RCS thruster malfunctions, but successfully docked to ISS. | — | Success |
| Crew Flight Test (patch) |
S3.2 Calypso |
June 5, 2024 | September 7, 2024 | Crewed flight test to ISS. Landed uncrewed due to malfunctioning RCS thrusters. | Partial failure | |
| Starliner-1 | S2.2 | TBD[46] | TBD | TBA | Planned | |
| Starliner-2 | TBD | TBD | TBD | TBA | Planned | |
| Starliner-3 | TBD | TBD | TBD | TBA | Planned | |
NASA has only placed orders for three Starliner flights once the capsule is certified for operational use. Under the terms of its contract with Boeing, it has the option to purchase up to six operational flights, Starliner-1 through Starliner-6. However, it is unclear if it will be possible to operate that many missions before the scheduled retirement of the ISS in 2030.[132]
Technology partners
[edit]- Aerojet Rocketdyne, reaction control system and retrorockets[133]
- Airborne Systems, parachutes[134]
- Bigelow Aerospace, elements of crew capsule[20]
- Collins Aerospace, life support systems[135]
- David Clark Company, spacesuits[136]
- ILC Dover, airbags[137]
- Samsung, mobile communications technology[138]
- Spincraft, crew module pressure shell spin-form work[139]
See also
[edit]- List of crewed spacecraft
- Dream Chaser, a spaceplane under development
- Mengzhou, a human-rated spacecraft being developed in China
- Orel, a human-rated spacecraft being developed in Russia
- Orion (spacecraft) – American crewed spacecraft for the Artemis program
- SpaceX Dragon 2, human-rated capsule-type spacecraft
Notes
[edit]- ^ The first piloted Boeing Crew Flight Test mission carries 2 crew plus 344 kg (758 lb) of cargo.[4]
- ^ N22 designates that the Atlas V has no payload fairing, two solid rocket boosters, and two Centaur second-stage engines.
- ^ CST is an initialism for Crew Space Transportation.
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1 free-flight hot fire of 5 aft-facing thrusters prior to docking, returning 6-degree of freedom (DOF) axis control
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External links
[edit]- Boeing/Bigelow Crew Space Transport Vehicle on YouTube by Boeing (2010)
- Boeing Unveils America's First Space Taxi, Unlocks Possibilities for Future on YouTube by Boeing (2014)
- Reporter's Starliner Notebook
- Astronaut Doug Hines enters the Boeing Starliner for the first time during OFT-2
- Boeing Commercial Crew Transportation Capability Contract (CCtCap) - the fixed price contract with NASA for the Starliner program
Boeing Starliner
View on GrokipediaHistory
Origins and NASA Selection
The Boeing CST-100 Starliner originated within NASA's Commercial Crew Program (CCP), established to develop commercial crew transportation systems to the International Space Station (ISS) following the Space Shuttle program's retirement in 2011, thereby restoring independent U.S. human spaceflight capability.[15] Boeing proposed the CST-100 as a reusable, crewed capsule designed for up to seven astronauts, emphasizing land-based recovery via airbags and parachutes to enable rapid reuse and operations from multiple U.S. launch sites.[1] NASA's initial selection of Boeing occurred on February 1, 2010, under the Commercial Crew Development (CCDev) Phase 1, where the agency awarded the company an $18 million Space Act Agreement to perform preliminary design work, risk assessments, and subsystem demonstrations for the CST-100, drawing on Boeing's expertise from the ISS program.[16] This phase involved five companies sharing approximately $50 million in American Recovery and Reinvestment Act funds to foster early concept maturation.[17] Building on this, in April 2011, Boeing secured $92.3 million under CCDev Phase 2—the largest award in that round—for advancing key technologies such as thermal protection, autonomous docking, and abort systems.[18] Progression continued with the August 3, 2012, award of a $460 million Commercial Crew Integrated Capability (CCiCap) Space Act Agreement, selecting Boeing (alongside SpaceX and Sierra Nevada Corporation) to integrate the CST-100 with the United Launch Alliance Atlas V launch vehicle, conduct system-level testing, and prepare for certification.[19] The decisive operational selection came on September 16, 2014, when NASA awarded Boeing a $4.2 billion fixed-price Commercial Crew Transportation Capability (CCtCap) contract to finalize development, achieve NASA human-rating certification, and deliver up to six crewed ISS missions, establishing Boeing as one of two certified providers for redundancy in crew transport.[20][21] This contract value reflected Boeing's proposed per-seat cost of $90–100 million, higher than SpaceX's due to differences in system architecture and integration scope.[22]Development Contracts and Early Milestones
In 2010, Boeing initiated development of the CST-100 spacecraft as part of NASA's Commercial Crew Program, aiming to create a crew transportation system for the International Space Station.[1] The company received initial funding through the program's early phases, including a $92.3 million award under Commercial Crew Development (CCDev) Phase 2 on April 18, 2011, to refine the capsule's design, propulsion integration, and landing systems.[23] This phase focused on risk reduction and technology maturation, with Boeing demonstrating key elements such as autonomous docking simulations and airbag landing tests. Advancing to the Commercial Crew Integrated Capability (CCiCap) phase, NASA awarded Boeing a $460 million Space Act Agreement on August 15, 2012, to integrate spacecraft components, including the service module and launch vehicle compatibility with United Launch Alliance's Atlas V rocket.[24] Boeing completed all CCiCap milestones by October 2014, including preliminary and critical design reviews, hardware qualification tests, and software validation, which verified the spacecraft's structural integrity and environmental control systems.[25] These efforts culminated in the spacecraft achieving a design freeze and progressing toward flight hardware production. The pivotal contract came on September 16, 2014, when NASA selected Boeing for the Commercial Crew Transportation Capability (CCtCap) phase, awarding a $4.2 billion fixed-price contract to complete development, certification, and up to six operational missions transporting NASA astronauts to the ISS.[20] This agreement built on prior phases by mandating demonstration flights, with Boeing achieving its first CCtCap milestone in December 2014 through updated flight software and mission planning documentation.[26] Early post-contract milestones included ground-based integrated vehicle testing and abort system validations, setting the stage for subsequent flight hardware assembly at NASA's Kennedy Space Center. ![Boeing’s Wind Tunnel testing of the CST-100][float-right] Aerodynamic testing in wind tunnels, conducted as part of early design validation under CCDev and CCiCap, confirmed the capsule's stability during atmospheric entry and launch configurations.[1] These non-flight milestones ensured compliance with NASA's human-rating standards prior to hardware fabrication.Flight Testing and Key Missions
Flight testing of the Boeing Starliner began with ground-based evaluations and progressed to integrated vehicle demonstrations. A key early milestone was the Pad Abort Test conducted on November 4, 2019, at White Sands Missile Range in New Mexico, where the spacecraft's launch abort engines fired successfully, propelling the uncrewed capsule away from a simulated launch mount to an altitude of approximately 1,500 feet before parachute deployment and soft landing.[27] Although one of the three main parachutes failed to fully deploy, resulting in a descent under two parachutes, NASA officials deemed the test successful overall, validating the abort system's performance under nominal conditions.[27] Boeing confirmed that propulsion, guidance, and flight systems operated as planned.[28] The first Orbital Flight Test (OFT-1) launched uncrewed on December 20, 2019, atop a United Launch Alliance Atlas V rocket from Cape Canaveral Space Force Station.[29] A critical software anomaly in the Mission Elapsed Time calculation caused the spacecraft to receive incorrect time data from the rocket, triggering uncommanded firings of reaction control system thrusters and preventing rendezvous with the International Space Station (ISS).[29] The capsule achieved a stable low Earth orbit but consumed excessive propellant, leading to mission controllers to forgo docking and command a safe reentry after two days, with landing in the White Sands Missile Range on December 22, 2019.[30] NASA's subsequent investigation identified 61 corrective actions, including software fixes and enhanced testing protocols to address the integrated system failures.[30] OFT-2, the second uncrewed orbital demonstration, lifted off on May 22, 2022, successfully docking autonomously to the ISS Harmony module on May 24 after overcoming initial thruster pressure drops affecting two of 12 orbital maneuvering engines.[31] The spacecraft remained at the station for four days, conducting checkout operations, before undocking on May 25 and landing intact at White Sands under parachutes and airbags.[31] This flight validated key capabilities such as autonomous docking, space-to-ground communication, and safe return, paving the way for crewed operations despite the minor propulsion anomalies resolved in flight.[31] The Crew Flight Test (CFT), Starliner's first human spaceflight, launched on June 5, 2024, carrying NASA astronauts Barry "Butch" Wilmore and Sunita "Suni" Williams to the ISS aboard an Atlas V from Cape Canaveral.[10] Pre-launch helium leaks in the service module's propulsion system persisted post-liftoff, expanding to multiple leaks, while five of 28 reaction control thrusters malfunctioned during the approach to docking, which was achieved manually on June 6 after delays.[10] Extended station-keeping revealed ongoing propulsion uncertainties, prompting NASA on August 24, 2024, to return the astronauts via SpaceX's Crew Dragon on the Crew-9 mission and fly Starliner uncrewed.[10] The capsule undocked on September 6, 2024, and landed successfully in New Mexico on September 7, enabling post-flight analysis of the thruster degradation linked to helium ingress and overheating.[32] As of October 2025, certification for operational missions remains pending further ground testing and anomaly resolution.[33]Post-Crew Flight Test Developments
Following the Crew Flight Test on June 5, 2024, which encountered multiple helium leaks and degradation in reaction control system (RCS) thrusters during ascent and docking operations, NASA opted on August 24, 2024, to return the Starliner spacecraft uncrewed to prioritize astronaut safety amid unresolved propulsion risks.[10] The vehicle undocked from the International Space Station on September 6, 2024, and landed successfully in New Mexico at 10:01 p.m. MDT that day, marking the first autonomous reentry and touchdown for the program.[34] Post-landing inspections revealed charring and degradation in the "doghouse" compartment housing RCS thrusters and plumbing, attributed to overheating from prolonged firings and design vulnerabilities in propellant routing.[35] NASA astronauts Barry E. Wilmore and Tracy C. Dyson, originally planned for an eight-day mission, remained aboard the ISS for 286 days before returning to Earth on March 18, 2025, via SpaceX's Crew-9 Dragon capsule alongside its crew, after delays tied to thruster reliability concerns prevented a crewed Starliner return.[36] Ground-based testing replicated in-flight thruster overheating, where seals degraded after 25 cycles—far short of the 115 required for certification—prompting deeper investigations into Teflon degradation and helium leak propagation through the propulsion manifold.[37] Boeing and NASA joint reviews, ongoing into October 2025, have not fully resolved root causes, with an independent safety panel noting persistent risks in thruster redundancy and thermal management as barriers to certification.[38][39] In response, NASA evaluated requiring a third uncrewed demonstration flight to demonstrate fixes before operational missions, as announced in March 2025, amid Boeing's broader engineering challenges.[40] By July 2025, preparations shifted toward an early 2026 launch window for a potential uncrewed or post-certification test, contingent on resolving propulsion anomalies, with certification reviews extending into late 2025.[41][42] As of October 2025, no firm schedule exists for Starliner-1, the first operational crewed flight, with NASA emphasizing data-driven risk mitigation over expedited timelines.[14] Leadership changes, including the January 2025 return of former Starliner program head Mark Nappi, aim to accelerate anomaly closures, though systemic delays have compressed the program's viability window for ISS rotations.[43]Design and Technical Specifications
Overall Configuration and Components
The Boeing CST-100 Starliner is a two-module spacecraft consisting of a reusable crew module and an expendable service module, designed for transporting crew and cargo to low Earth orbit destinations such as the International Space Station. The crew module serves as the pressurized habitat for astronauts, featuring a conical shape with a diameter of 4.56 meters and capacity for up to seven occupants or a mix of personnel and cargo, though NASA operational missions typically carry four crew members.[4][1] The service module, positioned beneath the crew module, provides essential support functions including propulsion, power generation, and attitude control during ascent and orbital phases.[4] The crew module's primary structural element is a weldless aluminum pressure vessel that forms the habitable volume, incorporating a honeycomb-like internal structure to minimize mass while maintaining structural integrity. This vessel is encased within an outer aeroshell equipped with a phenolic-impregnated carbon ablator (PICA) heat shield for reentry protection, along with thermal tiles and blankets on the backshell. Key integrated components include the NASA Docking System for station interface, multiple windows for situational awareness, and airbag-assisted landing gear deployed post-parachute deceleration using three main and two drogue parachutes. The module is engineered for reusability across up to ten missions with a six-month refurbishment turnaround.[1][4] The cylindrical service module integrates propulsion elements such as reaction control system thrusters, orbital maneuvering and attitude control thrusters, and four pusher abort engines for launch escape capability, supported by fuel and helium tanks. It also houses solar arrays capable of generating over 2.9 kW of power, routed to batteries for storage, and additional subsystems for thermal management and avionics support. Unlike the crew module, the service module is discarded prior to reentry, with each mission requiring a new unit.[4][1]Propulsion and Attitude Control Systems
The Boeing CST-100 Starliner's propulsion and attitude control systems are distributed between the crew module and the detachable service module, enabling orbital insertion, maneuvering, precise orientation, and safe reentry. The service module houses the primary orbital propulsion elements, including 20 Orbital Maneuvering and Attitude Control (OMAC) thrusters, each delivering 1,500 lbf (6.7 kN) of thrust, provided by L3Harris.[44] These hypergolic engines, fueled by monomethylhydrazine (MMH) and nitrogen tetroxide (NTO), support major velocity changes such as orbit raising and deorbit burns, while also contributing to coarse attitude adjustments during flight.[44] Attitude control during the bulk of the mission relies on 28 Reaction Control System (RCS) thrusters integrated into the service module, arranged in clusters for three-axis stability and fine maneuvering.[44] These thrusters, also hypergolic and operating with MMH/NTO, provide thrust levels around 85-100 lbf (380-440 N) each, ensuring the spacecraft maintains proper orientation for solar array deployment, docking, and trajectory corrections.[45] The system incorporates redundant helium pressurization for propellant tanks, though helium leaks observed in the 2024 Crew Flight Test (CFT) mission highlighted vulnerabilities in seal integrity under prolonged thermal cycling.[7] For reentry and post-service module separation, the crew module employs 12 MR-104J RCS thrusters, monopropellant units using hydrazine that generate approximately 100 lbf (440 N) each.[44] These thrusters, supplied by L3Harris, handle final attitude control to align the heat shield for atmospheric entry, operating independently of the service module's systems. During the CFT mission launched on June 5, 2024, multiple service module RCS thrusters experienced performance degradation, with five failing initially due to overheating and valve issues, necessitating software workarounds and extended testing before crew return approval.[46] The launch abort system integrates four RS-88 engines mounted at the base of the crew module, each capable of 40,000 lbf (178 kN) thrust using hypergolic propellants for rapid escape from launch vehicle anomalies.[44] These engines enable both low-altitude and high-altitude aborts, with vector control for trajectory shaping, and were successfully demonstrated in a November 4, 2019, pad abort test.[47] Overall redundancy across thruster clusters allows fault-tolerant operation, though CFT anomalies underscored integration challenges between propulsion hardware and flight software.[48]Life Support and Crew Systems
The Environmental Control and Life Support System (ECLSS) for the Boeing CST-100 Starliner, supplied by Collins Aerospace, maintains a habitable cabin environment by regulating atmospheric composition, pressure, temperature, and humidity for missions lasting up to several months when docked to the International Space Station (ISS).[49] [50] Key components include air revitalization assemblies for carbon dioxide removal, oxygen supply systems, cabin fans for circulation, heat exchangers for thermal management, pressure control sensors, and a humidity control subassembly (HCS) employing Nafion bundle technology to extract water vapor from cabin air.[51] [52] Unlike fully closed-loop systems on the ISS, Starliner's ECLSS operates primarily in open-loop mode suited for short-duration free-flight (approximately 60 hours on batteries) and extended docked operations drawing station power, relying on stored consumables rather than extensive recycling.[53] Crew systems emphasize ergonomic interfaces and redundancy for up to seven astronauts in low-Earth orbit configurations, though NASA missions typically carry four.[1] Seating features customizable 3D-printed inserts within metal frames, adjustable in up to five million configurations to accommodate diverse body sizes from the 5th percentile female to 95th percentile male, informed by anthropometric testing including contributions from smaller-statured engineers.[54] Avionics include fault-tolerant computing with glass cockpit displays for primary flight data, eschewing touchscreen inputs in favor of manual controls and simplified interfaces to reduce pilot workload during nominal and contingency operations; crew can assume manual control via these systems, validated in ground and flight tests.[55] [56] Supplemental wireless connectivity supports tablet-based secondary interfaces for procedures, entertainment, and non-critical tasks.[1] Waste management encompasses urine and fecal collection with stowage provisions, though early testing revealed potential issues such as loose connections in components, addressed prior to crewed flights.[4] Radiation shielding relies on the spacecraft's aluminum pressure vessel and water/glycol coolant loops for partial attenuation of galactic cosmic rays and solar particles during transit and docked phases, adequate for nominal mission durations but raising concerns for extended undocked exposure, as evidenced by dose estimates during the 2024 Crew Flight Test delays.[57] ECLSS performance, including sensor redundancy like carbon dioxide monitoring, was demonstrated in uncrewed Orbital Flight Test-2 on May 25, 2022, and the crewed flight on June 5, 2024, confirming system reliability under operational loads.[4] [58]Reentry and Landing Mechanisms
The Boeing Starliner crew module features an ablative heat shield made from the company's proprietary Lightweight Ablator material, designed to withstand peak reentry temperatures of approximately 3,000°F (1,650°C) during atmospheric interface.[59][60] This shield protects the capsule's base as it descends base-first at a nominal entry angle, leveraging the vehicle's inherent lifting characteristics for trajectory control and reduced g-loading, peaking at around 4-5 g.[61] Prior to reentry, the service module executes a deorbit burn using its Orbital Maneuvering and Attitude Control (OMAC) thrusters, followed by separation from the crew module, allowing independent atmospheric entry.[62] Descent begins with hypersonic flight, transitioning to supersonic speeds where aerodynamic stability is maintained via reaction control system thrusters until parachute deployment. At roughly 30,000 feet (9 km) altitude and 700-800 km/h velocity, two drogue parachutes deploy via pyrotechnic mortars to stabilize the capsule and reduce speed to about 250 mph (400 km/h).[63] These drogues then jettison, enabling deployment of three main parachutes, which further decelerate the vehicle to terminal velocity of approximately 15-20 mph (24-32 km/h).[64] The main heat shield separates during the main parachute phase at around 5,000 feet (1.5 km), exposing the underside where three inflatable airbags deploy and inflate to absorb impact energy.[61] This system reduces touchdown velocity to 2-3 mph (3-5 km/h), enabling a soft landing on desert terrain without reliance on water recovery.[65] The design incorporates redundancy, demonstrated safe with only two main parachutes in testing, as airbags compensate for higher loads.[65] Designated landing zones include White Sands Missile Range in New Mexico, Willcox Playa in Arizona, and Dugway Proving Ground in Utah, selected for flat terrain and recovery infrastructure.[31] Ground tests validated the parachute system through a series of drops completed by December 2020, simulating nominal and off-nominal conditions.[64] Orbital Flight Test-2 on May 25, 2022, confirmed full deployment of all three main parachutes and airbag inflation during landing at White Sands, achieving a peak deceleration of 5.5 g.[66] The Crew Flight Test uncrewed return on September 6, 2024, similarly executed nominal reentry and landing procedures at the same site, with airbags ensuring minimal impact forces.[67] This land-based approach marks the first for a U.S. orbital crew capsule since the 1960s, avoiding corrosion and biological contamination risks associated with ocean splashdown.[61]Launch and Mission Operations
Integration with Launch Vehicle
The Boeing CST-100 Starliner spacecraft integrates with the United Launch Alliance Atlas V rocket through a specialized launch vehicle adapter (LVA) that mates the Starliner's service module directly to the Centaur upper stage, eliminating the need for a traditional payload fairing and exposing the crew module during ascent to facilitate abort capabilities.[68][69] The LVA incorporates an aeroskirt to mitigate aerodynamic loads on the vehicle stack during launch, ensuring structural integrity under dynamic pressure conditions.[68] This adapter also handles critical interfaces, including electrical connections, propellant umbilicals, and separation mechanisms for post-launch spacecraft deployment.[70] Pre-launch integration occurs primarily at Kennedy Space Center's Space Launch Complex 41, beginning with the assembly of the Atlas V in the Vertical Integration Facility (VIF). The process involves stacking the RD-180-powered first stage core with two Aerojet Rocketdyne AJ-60A solid rocket boosters (for crewed configurations like the N22 class), followed by mating the RL10-powered Centaur upper stage.[71][56] The Starliner spacecraft, comprising the crew module and service module, is then transported from Boeing's processing facility via a specialized trailer and hoisted using a crane for precise alignment and bolting to the LVA atop the Centaur.[72][71] For the Crew Flight Test (CFT) on June 5, 2024, this mating was completed on April 16, 2024, after which the integrated stack underwent joint integrated vehicle testing, including avionics health checks, propulsion system verifications, and environmental simulations to confirm compatibility between the spacecraft and rocket systems.[71][73] Once mated, the full vehicle—standing approximately 172 feet (52 meters) tall—is rolled out to the launch pad on a mobile launcher for final closeout operations, such as loading hypergolic propellants into the Starliner service module, installing the crew, and disconnecting ground umbilicals.[73][74] This integration approach leverages the Atlas V's proven reliability, with over 90 launches since 2006, while adapting it for human spaceflight through enhanced abort system interfaces that allow the Starliner's launch escape system to separate the crew module from the rocket in emergencies throughout ascent.[69][75]Nominal Mission Profile
The Boeing CST-100 Starliner spacecraft launches from Space Launch Complex 41 at Cape Canaveral Space Force Station, Florida, aboard a United Launch Alliance Atlas V 421 configuration rocket equipped with two solid rocket boosters and a Centaur upper stage.[58][1] Following ignition of the Atlas V's RD-180 main engine and solid rocket boosters at T+0 seconds, the vehicle ascends vertically, performs a pitch-over maneuver approximately 10 seconds after liftoff, and separates the boosters at around T+1:45, with stage separation from the Centaur occurring at T+3:30 to T+4:00.[58] The Starliner crew module separates from the Centaur upper stage roughly 10-12 minutes after launch, after which its service module thrusters execute initial orbital insertion burns to circularize the orbit at an altitude of approximately 250 nautical miles.[58] Post-insertion, Starliner enters a nominal free-flight phase lasting about 24 hours, during which autonomous systems perform checkouts of propulsion, guidance, navigation, and control subsystems, including reaction control system firings for trajectory adjustments.[58] Rendezvous operations begin with ground-relative phasing maneuvers using the service module's Aerojet Rocketdyne OMAC thrusters, progressing through proximity operations to align with the ISS, typically approaching from below and behind the station's velocity vector.[58] Docking occurs autonomously to the forward-facing International Docking Adapter on the Harmony module's forward port, with contact and capture expected within 24-28 hours of launch; the crew module's NASA Docking System ensures soft capture and hard mate, followed by hatch opening for crew transfer.[58][1] Once docked, Starliner supports crew rotations of up to four astronauts plus cargo for NASA-contracted ISS missions, with the spacecraft remaining attached as a crewed safe haven capable of independent operation for up to seven days in contingency scenarios.[1] Nominal stay durations for operational missions range from short-duration tests (e.g., one week) to extended rotations of approximately 180-210 days, during which the crew performs station handovers, scientific research support, and system monitoring via integrated life support and data interfaces.[58][1] Undocking initiates with crew ingress to Starliner, hatch closure, and leak checks, followed by autonomous separation using docking mechanism springs and low-thrust maneuvers to achieve a safe distance of about 1 kilometer from the ISS.[58] A deorbit burn, executed by the service module's main engines, targets a reentry trajectory with perigee at 50-60 nautical miles, slowing the spacecraft from orbital velocity of approximately 17,500 mph.[58] Reentry involves peak heating at Mach 25, with the phenolic-impregnated carbon ablator heat shield managing temperatures up to 3,500°F; drogue parachutes deploy at 30,000 feet, followed by three main parachutes at 18,000 feet for deceleration to 4-5 mph, augmented by airbag inflation upon ground proximity.[58] Landing occurs at one of three primary sites in the southwestern United States—White Sands Space Harbor, New Mexico; Willcox Playa, Arizona; or Dugway Proving Ground, Utah—with weather criteria limiting winds to under 15 mph at surface level and visibility above 3 miles.[31] Post-landing, recovery teams secure the capsule within minutes, followed by crew extraction and spacecraft safing for potential refurbishment and reuse up to 10 times.[1][58]Docking, Stay, and Undocking Procedures
The Boeing Starliner spacecraft employs the NASA Docking System (NDS) for autonomous docking to the International Space Station (ISS), enabling independent connection without external aids such as robotic arms.[76] The procedure begins with rendezvous operations, where Starliner approaches the ISS from behind and below, using relative navigation sensors including the Honeywell SIGI (Space Integrated GPS/INS) for precise guidance.[77] During the Crew Flight Test (CFT) on June 6, 2024, Starliner achieved soft capture at the forward port of the Harmony module after holding at a 10-meter distance for system checks, followed by hard capture to establish a pressurized seal, allowing crew hatch opening approximately two hours later.[78] Astronauts monitor the autonomous process but can intervene manually if anomalies occur, such as thruster performance issues observed pre-docking in the CFT mission.[79] Once docked, Starliner remains attached to the ISS via the NDS mechanism, supporting crew transfer, power sharing, and data exchange through umbilical connections established post-hard capture.[78] Nominal stay durations are planned for about eight days, during which the crew conducts joint operations, including station familiarization, emergency drills, and scientific experiments, while the spacecraft serves as a lifeboat.[58] In the CFT, the stay extended significantly beyond the initial limit of 45 days due to propulsion concerns, including helium leaks and thruster malfunctions, enabling additional testing and research opportunities; the vehicle demonstrated capability for prolonged docking up to several months.[80][10] Undocking follows a reversal of docking sequences, initiated autonomously with crew command confirmation. The NDS disengages latches for separation, after which Starliner performs departure burns using its reaction control system thrusters to achieve safe distance from the ISS.[81] For the CFT, uncrewed undocking occurred on September 6, 2024, from the Harmony forward port, with the spacecraft executing a deorbit burn leading to reentry and landing in New Mexico roughly six hours later, validating the procedure sans crew.[82][58] This autonomous undock and return profile mirrors nominal operations, ensuring minimal station interference.Program Challenges and Criticisms
Delays and Cost Overruns
The Commercial Crew Transportation Capability (CCtCap) contract awarded to Boeing by NASA on September 16, 2014, was valued at $4.2 billion on a fixed-price basis, encompassing spacecraft development, certification, and up to seven missions (one crewed flight test and six operational) to the International Space Station, with an initial expectation of operational readiness by 2017.[83] This timeline proved overly optimistic, as the program encountered repeated setbacks stemming from software anomalies, propulsion system failures, and integration challenges with the Atlas V launch vehicle. The first uncrewed Orbital Flight Test (OFT-1) launched on December 20, 2019, but aborted rendezvous due to flight software errors that caused excessive thruster firings and depleted propellant reserves.[84] Subsequent efforts to conduct a second uncrewed test (OFT-2) were indefinitely postponed in November 2021 amid discoveries of degraded propulsion valves and helium leaks, prompting Boeing to pivot resources toward the crewed flight test (CFT) while addressing these issues through redesigns and extensive ground testing.[85] The CFT, originally targeted for as early as 2022, faced serial delays due to thruster malfunctions observed during hot-fire tests, parachute system qualifications, and data recorder wiring concerns, ultimately launching on June 5, 2024—nearly a decade after contract award and seven years behind the original schedule.[86] Post-launch, helium leaks and thruster performance degradation during flight extended ground analysis periods, delaying the vehicle's return from an planned 8-10 days to an uncrewed landing on September 6, 2024, while the crew remained aboard the ISS until repatriation via SpaceX Crew Dragon in March 2025.[12] These delays have amplified costs significantly under the fixed-price structure, where Boeing absorbs overruns beyond NASA's payments. As of February 2025, Boeing reported cumulative losses exceeding $2 billion on the Starliner program, including a $523 million charge in 2024 alone tied to CFT delays and certification uncertainties.[87] A November 2019 NASA Office of Inspector General audit attributed much of the escalation to Boeing's schedule slippage, projecting per-seat costs at $90 million—over 60% higher than SpaceX's $55 million—due to prolonged development absorbing fixed mission allocations without additional NASA funding.[88] The audit further noted NASA's authorization of nearly $300 million in extra incentives to Boeing amid fears of program withdrawal, underscoring how delays eroded fiscal discipline despite the contract's intent to incentivize efficiency.[89] Overall, the overruns reflect cascading effects from early engineering missteps, such as underestimating software complexity and propulsion reliability, compounded by Boeing's internal management strains from concurrent projects like the 737 MAX remediation.[90] In November 2025, NASA and Boeing modified the CCtCap contract, reducing its value by $768 million to $3.732 billion and scaling back the number of committed missions from six to four (with two additional as options), to prioritize safe certification of the Starliner system in 2026 and validation of propulsion upgrades following prior anomalies. This change shifts emphasis toward addressing technical challenges and aligning future flights with International Space Station requirements through 2030.[91][92][93] The contract incorporates standard Federal Acquisition Regulation (FAR) clauses, including Termination for Convenience of the Government, allowing NASA to terminate at any time for any reason, with Boeing entitled to settlement for work performed, reasonable costs, and profit on completed efforts (no anticipatory profits), and Termination for Default, permitting termination for failure to perform, potentially holding Boeing liable for excess reprocurement costs and other damages. No unique or specific penalties beyond these standard provisions are detailed in public sources. As of February 2026, NASA has not exercised termination despite ongoing program challenges.[94]Technical Failures and Safety Concerns
The Boeing CST-100 Starliner spacecraft has experienced recurrent propulsion system anomalies, including helium leaks and reaction control system (RCS) thruster failures, during uncrewed and crewed test flights, prompting NASA to prioritize safety over nominal return profiles. These issues stem from the service module's hydrazine-based thrusters, which rely on pressurized helium for propellant flow, where seal degradation and potential overheating have compromised performance reliability.[95][96] During the second Orbital Flight Test (OFT-2) on May 20, 2022, two of the 20 orbital maneuvering and attitude control (OMAC) thrusters failed to ignite properly during the initial deorbit preparation burn, though spacecraft redundancies enabled docking with the International Space Station (ISS) after a 48-hour delay. Post-mission analysis revealed helium leaks in the propulsion lines, attributed to degraded seals, alongside off-nominal RCS thruster firings that extended the test duration beyond planned parameters. Ground investigations identified corrosive buildup in propulsion valves, which had previously scrubbed a launch attempt in August 2021, further highlighting material durability challenges in the system's plumbing.[97][98] The Crew Flight Test (CFT), launched uncrewed initially but crewed on June 5, 2024, with NASA astronauts Barry E. Wilmore and Tracy C. Dyson aboard, encountered escalated propulsion failures: four helium leaks manifested within hours of liftoff, increasing to five by rendezvous, while five of 28 RCS thrusters degraded or failed during docking approach on June 6, with some exhibiting overheating and reduced thrust output. Boeing and NASA engineers conducted in-flight hot-firing tests, recovering four thrusters, but persistent uncertainty over long-duration performance—linked to probable Teflon seal erosion allowing propellant coking—precluded confidence in deorbit maneuvers. These anomalies echoed OFT-2 patterns but at higher severity, as ground simulations replicated thruster degradation after prolonged exposure to hypergolic propellants.[99][100] Parachute system concerns compounded reentry risks, with pre-CFT reviews in June 2023 uncovering that "soft links" (fabric connectors) in the main parachute risers failed to meet load-strength specifications under full-mass drop tests, alongside flammable wiring harnesses in the abort system violating certification standards. Although redesigns qualified all three drogue and main parachutes for crewed use—evidenced by the uncrewed CFT landing on September 6, 2024, with full deployment—the initial two-parachute baseline had reduced deceleration margins, potentially exceeding human g-limits in off-nominal scenarios. Earlier drop tests, including a 2019 qualification failure where a pilot chute detached prematurely due to insecure lanyard connections, underscored iterative fixes needed for airbag-integrated touchdowns.[101][102] NASA's August 24, 2024, decision to return Wilmore and Dyson via SpaceX's Crew-9 Dragon in February 2025, while undocking Starliner uncrewed, reflected causal risks of thruster unreliability propagating to attitude control loss during reentry, potentially yielding orbital insertion errors or uncontrolled descent. Independent safety panels cited insufficient empirical data on anomaly recurrence under mission stresses, deeming the 1-in-270 loss-of-crew probability threshold unmet without exhaustive validation. Boeing maintained adequate helium reserves and thruster margins for uncrewed operations, which proved viable in the September landing, but NASA emphasized flight-test uncertainties—distinct from routine missions—warranting empirical caution over manufacturer assurances. By January 2025, joint reviews reported progress in root-cause closure, including seal material upgrades, though certification for operational flights remains pending further integrated testing.[10][103][82]Management and Oversight Issues
Boeing's management of the Starliner program has been criticized for inadequate quality control processes that failed to meet NASA's standards, with known deficiencies persisting despite contractual obligations. A 2024 NASA Office of Inspector General report highlighted that Boeing's systems for tracking non-conformance issues and implementing corrective actions were incomplete, allowing problems such as thruster malfunctions and helium leaks during the Crew Flight Test (CFT) mission on June 5, 2024, to go unaddressed prior to launch.[104] These lapses stemmed from Boeing's broader adoption of lean manufacturing practices, which prioritized cost reduction over rigorous engineering oversight, resulting in rushed testing and overlooked integration issues between software and hardware.[105] Whistleblower accounts have exposed a corporate culture at Boeing that discourages reporting of safety concerns, with employees facing retaliation for raising quality assurance flags related to spacecraft production. In October 2024, Boeing space division workers filed lawsuits alleging isolation and reprisal for highlighting defects, reflecting a systemic undervaluation of employee input on safety and quality.[106] This environment contributed to undetected software errors during the Orbital Flight Test-1 (OFT-1) in December 2019, where mission elapsed time clock misconfigurations—stemming from unverified ground software uploads—prevented orbital rendezvous with the International Space Station (ISS).[107] NASA's oversight mechanisms have also drawn scrutiny for insufficient rigor in reviewing Boeing's self-reported data and processes, enabling multiple anomalies to evade pre-flight detection. NASA Commercial Crew Program manager Steve Stich acknowledged in July 2020 that inadequate agency oversight permitted software deficiencies to proliferate during OFT-1 preparations, including failures in command verification and service module disposal logic.[108] During the CFT, cascading thruster failures and propellant leaks—traced to degraded seals and valve blockages—highlighted ongoing gaps in joint anomaly resolution, with NASA relying heavily on Boeing's internal assessments rather than independent validations.[11] These management and oversight shortfalls exacerbated cost overruns, with Boeing absorbing over $2 billion in losses on the fixed-price Commercial Crew Transportation Capability contract by February 2025, primarily due to repeated delays from unmitigated technical risks and inefficient resource allocation.[109] Boeing's leadership has since reported incremental improvements in cost containment through enhanced program controls, but persistent certification hurdles underscore the need for cultural reforms to prioritize empirical validation over schedule pressures.[110]Comparative Performance Against Competitors
In NASA's Commercial Crew Program, Boeing's CST-100 Starliner primarily competes with SpaceX's Crew Dragon for crew transportation to the International Space Station (ISS), both selected under the 2014 Commercial Crew Transportation Capability (CCtCap) contracts.[111] NASA allocated $4.2 billion to Boeing and $2.6 billion to SpaceX for development, certification, and initial operational missions, reflecting an expectation of dual redundancy despite the cost disparity.[111] Boeing's program, however, has exceeded its budget by over $2 billion as of early 2025, with total expenditures at least double those of Crew Dragon due to repeated technical revisions and delays.[112] [113] Schedule adherence further differentiates the vehicles: SpaceX completed Crew Dragon's demonstration mission with crew in May 2020, achieving full operational certification shortly thereafter and executing over 10 crewed ISS rotations by October 2025.[114] Starliner, by comparison, suffered a software failure during its 2019 orbital flight test, requiring a redo in 2022, and its June 5, 2024, Crew Flight Test (CFT) experienced multiple reaction control system thruster failures and helium leaks in the service module, aborting docking and resulting in an uncrewed reentry on September 7, 2024, while the two test astronauts returned via Crew Dragon in March 2025.[10] As of October 2025, Starliner certification remains unresolved, with NASA targeting an uncrewed post-certification flight no earlier than early 2026 pending propulsion and software fixes.[41] [115] Per-seat operational costs amplify the gap: A 2019 NASA Inspector General audit estimated $90 million per seat for Starliner versus $55 million for Crew Dragon, a 60% premium for Boeing driven by fixed-price contract milestones unmet and lower flight cadence.[116] SpaceX's costs have adjusted upward to approximately $67-72 million per seat in extended contracts but benefit from economies of scale through higher mission volume and reusability, with capsules like Endeavour completing multiple flights.[117] Starliner's projected costs remain higher absent proven operational tempo. Both spacecraft share core specifications, including capacity for up to seven astronauts, autonomous ISS docking via International Docking System Standard ports, and integrated launch abort systems—Starliner's using pyrotechnic separation with an Atlas V rocket, versus Crew Dragon's integrated SuperDraco thrusters on Falcon 9.[118] Crew Dragon demonstrates superior reliability in reaction control (propellant-fed Draco thrusters with extensive ground testing) and reusability, having completed crewed reentries with airbag-landings in ocean splashdowns across 15+ flights including private missions.[114] Starliner's airbag-assisted ground landing and storable-propellant service module, while innovative for rapid turnaround, have shown vulnerabilities in flight, including 28 of 48 thrusters degrading during CFT and unverified long-duration stability.[119]| Aspect | Boeing Starliner | SpaceX Crew Dragon |
|---|---|---|
| NASA Development Funding | $4.2 billion[111] | $2.6 billion[111] |
| First Crewed Attempt | June 2024 (docking failed)[10] | May 2020 (successful)[114] |
| Crewed ISS Missions (Oct 2025) | 0 | >10[114] |
| Est. Per-Seat Cost | $90 million[116] | $55-72 million[116] [117] |
| Certification Status | Pending (2026 target)[41] | Certified since 2020[114] |
