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Boeing Starliner
Boeing Starliner Spacecraft 2 approaching the ISS in May 2022, during Orbital Flight Test 2
ManufacturerBoeing Defense, Space & Security
Country of originUnited States
OperatorBoeing Defense, Space & Security
ApplicationsISS crew transport
Websiteboeing.com/starliner
Specifications
Spacecraft typeCapsule
Payload capacityTo ISS: 4 crew and 100 kg (220 lb) cargo[3][a]
Crew capacityUp to 7
Volume11 m3 (390 cu ft)[5]
RegimeLow Earth orbit
Design life
  • 60 hours (free flight)[1]
  • 7 months (docked)[2]
Dimensions
Length5.03 m (16.5 ft) (Capsule and SM)[6]
Diameter4.56 m (15 ft)[6]
Production
StatusActive
Built3
Operational2
Retired1
Maiden launchUncrewed: December 20, 2019
Crewed: June 5, 2024
Related spacecraft
Launch vehicleAtlas 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]
2018 Starliner assembly process

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]
Operational crewed orbital spacecraft as of 2025
Starliner pressure vessel at the former Orbiter Processing Facility, showing its isogrid construction, October 2011
Wind-tunnel testing of Starliner model, December 2011

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]

Starliner spacecraft consisting of capsule and service module

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:

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[disputeddiscuss]), 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.[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]
An Erickson Skycrane (foreground) frames the Starliner (background) in 2012. During testing, the helicopter dropped the capsule from about 7,000 feet (2,000 m) to test its parachutes and airbags.
A close up look at Starliner's six airbags during drop testing

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]

Starliner Spacecraft 1 ignites its RS-88 abort engines during the Boeing Pad Abort Test in November 2019.

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 upper and lower domes of Boeing Starliner Calypso being mated inside the Commercial Crew and Cargo Processing Facility (C3PF) at Kennedy Space Center on June 19, 2018
Boeing Starliner Calypso landed at White Sands Missile Range in New Mexico following an uncrewed Orbital Flight Test in December 2019.

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]
Boeing Starliner Spacecraft 2 ahead of landing at White Sands Missile Range in New Mexico following OFT-2 in May 2022

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]
Boeing Starliner Calypso launches on the Crew Flight Test atop an Atlas V rocket.
Boeing Starliner Calypso docked to the ISS during the Crew Flight Test

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]
Artist's impression of a Boeing Starliner docking to the ISS

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, 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
  • 2d 1h 22m (OFT)
  • 93d 13h 9m (CFT)
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.

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]

See also

[edit]

Notes

[edit]

References

[edit]
[edit]
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The Boeing CST-100 Starliner is a reusable crew capsule spacecraft developed by The Boeing Company under contract with NASA to ferry astronauts to and from the International Space Station as part of the agency's Commercial Crew Program. Designed to accommodate up to seven passengers or a combination of crew and cargo for missions in low-Earth orbit, it employs a service module for propulsion and a crew module that returns to Earth via parachute and airbag-assisted landing on solid ground. Development of Starliner originated in the early 2010s, with NASA awarding Boeing a $4.2 billion fixed-price contract in September 2014 to complete design, construction, testing, and certification for operational crewed flights to the ISS. The program encountered its first major setback during the initial uncrewed Orbital Flight Test in December 2019, when software errors prevented the spacecraft from reaching the station and led to excessive thruster firings that compromised its ability to safely return. A successful redo, Orbital Flight Test-2, occurred in May 2022, achieving docking with the ISS and a safe landing after an eight-day mission. The long-delayed Crew Flight Test launched on June 5, 2024, carrying NASA astronauts Barry "Butch" Wilmore and Sunita Williams to orbit aboard an Atlas V rocket, but helium leaks and multiple reaction control system thruster malfunctions during approach to the station prompted NASA to deem the vehicle unsafe for crewed return. These propulsion anomalies, which Boeing attributed to potential degradation from prolonged firing and seal issues, extended the astronauts' stay on the ISS until their return via SpaceX's Crew Dragon in February 2025, while the uncrewed Starliner capsule landed autonomously in on September 7, 2024. As of October 2025, investigations into the root causes continue, with and targeting a return-to-flight no earlier than early 2026—potentially uncrewed—to validate fixes before pursuing certification for operational missions, amid ongoing scrutiny over cost overruns exceeding $1.5 billion beyond the original contract and questions about the program's viability compared to competitors.

History

Origins and NASA Selection

The Boeing CST-100 Starliner originated within NASA's (CCP), established to develop commercial crew transportation systems to the (ISS) following the program's retirement in 2011, thereby restoring independent U.S. capability. 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. 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 to perform preliminary design work, risk assessments, and subsystem demonstrations for the CST-100, drawing on Boeing's expertise from the ISS program. This phase involved five companies sharing approximately $50 million in American Recovery and Reinvestment Act funds to foster early concept maturation. Building on this, in 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. Progression continued with the August 3, 2012, award of a $460 million Commercial Crew Integrated Capability (CCiCap) Space Act Agreement, selecting (alongside and ) to integrate the CST-100 with the , conduct system-level testing, and prepare for . The decisive operational selection came on September 16, 2014, when awarded a $4.2 billion fixed-price Commercial Crew Transportation Capability (CCtCap) contract to finalize development, achieve human-rating , and deliver up to six crewed ISS missions, establishing as one of two certified providers for redundancy in crew transport. This contract value reflected 's proposed per-seat cost of $90–100 million, higher than 's due to differences in system architecture and integration scope.

Development Contracts and Early Milestones

In 2010, Boeing initiated development of the CST-100 spacecraft as part of NASA's , aiming to create a transportation system for the . 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. This phase focused on risk reduction and technology maturation, with Boeing demonstrating key elements such as autonomous docking simulations and 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 components, including the service module and compatibility with United Launch Alliance's rocket. Boeing completed all CCiCap milestones by October 2014, including preliminary and critical reviews, hardware qualification tests, and software validation, which verified the 's structural integrity and environmental control systems. These efforts culminated in the 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. 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. 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. 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 in , 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. 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. Boeing confirmed that propulsion, guidance, and flight systems operated as planned. The first Orbital Flight Test (OFT-1) launched uncrewed on December 20, 2019, atop a rocket from . A critical software anomaly in the Mission Elapsed Time calculation caused the to receive incorrect time data from the rocket, triggering uncommanded firings of reaction control system thrusters and preventing rendezvous with the (ISS). The capsule achieved a stable but consumed excessive , leading to mission controllers to forgo docking and command a safe reentry after two days, with landing in the on December 22, 2019. NASA's subsequent investigation identified 61 corrective actions, including software fixes and enhanced testing protocols to address the integrated system failures. OFT-2, the second uncrewed orbital demonstration, lifted off on May 22, 2022, successfully docking autonomously to the ISS module on May 24 after overcoming initial thruster pressure drops affecting two of 12 orbital maneuvering engines. 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. 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. The Crew Flight Test (CFT), Starliner's first , launched on June 5, 2024, carrying astronauts Barry "Butch" Wilmore and Sunita "Suni" Williams to the ISS aboard an from . 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. Extended station-keeping revealed ongoing propulsion uncertainties, prompting on August 24, 2024, to return the astronauts via SpaceX's Crew Dragon on the Crew-9 mission and fly Starliner uncrewed. The capsule undocked on September 6, 2024, and landed successfully in on September 7, enabling post-flight analysis of the thruster degradation linked to helium ingress and overheating. As of October 2025, certification for operational missions remains pending further ground testing and anomaly resolution.

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. 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. 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. 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. Ground-based testing replicated in-flight thruster overheating, where seals degraded after 25 cycles—far short of the 115 required for —prompting deeper investigations into Teflon degradation and helium leak propagation through the propulsion manifold. 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 . In response, evaluated requiring a third uncrewed demonstration flight to demonstrate fixes before operational missions, as announced in March 2025, amid Boeing's broader challenges. 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. As of October 2025, no firm schedule exists for Starliner-1, the first operational crewed flight, with emphasizing data-driven risk mitigation over expedited timelines. 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.

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. The service module, positioned beneath the crew module, provides essential support functions including propulsion, power generation, and attitude control during ascent and orbital phases. The crew module's primary structural element is a weldless aluminum 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 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 Docking System for station interface, multiple windows for , and airbag-assisted 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. The cylindrical service module integrates propulsion elements such as 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 support. Unlike the crew module, the service module is discarded prior to reentry, with each mission requiring a new unit.

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 . These hypergolic engines, fueled by (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. Attitude control during the bulk of the mission relies on 28 (RCS) thrusters integrated into the service module, arranged in clusters for three-axis stability and fine maneuvering. 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. The system incorporates redundant 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. For reentry and post-service module separation, the crew module employs 12 MR-104J RCS thrusters, monopropellant units using that generate approximately 100 lbf (440 N) each. These thrusters, supplied by , handle final attitude control to align the for , 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 issues, necessitating software workarounds and extended testing before crew return approval. 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 anomalies. These engines enable both low-altitude and high-altitude aborts, with for trajectory shaping, and were successfully demonstrated in a , 2019, pad abort test. Overall redundancy across thruster clusters allows fault-tolerant operation, though CFT anomalies underscored integration challenges between hardware and flight software.

Life Support and Crew Systems

The Environmental Control and Life Support System (ECLSS) for the Boeing CST-100 Starliner, supplied by , maintains a habitable cabin environment by regulating atmospheric composition, pressure, temperature, and humidity for missions lasting up to several months when docked to the (ISS). Key components include air revitalization assemblies for , oxygen supply systems, cabin fans for circulation, heat exchangers for thermal management, pressure control sensors, and a humidity control subassembly (HCS) employing bundle technology to extract water vapor from cabin air. 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. Crew systems emphasize ergonomic interfaces and redundancy for up to seven astronauts in low-Earth orbit configurations, though missions typically carry four. 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. include fault-tolerant computing with 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. Supplemental wireless connectivity supports tablet-based secondary interfaces for procedures, entertainment, and non-critical tasks. 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. Radiation shielding relies on the spacecraft's aluminum 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. ECLSS performance, including sensor redundancy like 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.

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. 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. 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. Descent begins with , transitioning to supersonic speeds where aerodynamic stability is maintained via thrusters until 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). These drogues then jettison, enabling deployment of three main parachutes, which further decelerate the vehicle to of approximately 15-20 mph (24-32 km/h). The main separates during the main phase at around 5,000 feet (1.5 km), exposing the underside where three inflatable airbags deploy and inflate to absorb impact energy. This system reduces touchdown velocity to 2-3 mph (3-5 km/h), enabling a on without reliance on recovery. The design incorporates redundancy, demonstrated safe with only two main parachutes in testing, as airbags compensate for higher loads. Designated landing zones include in , Willcox Playa in , and in , selected for flat and recovery infrastructure. Ground tests validated the parachute system through a series of drops completed by December 2020, simulating nominal and off-nominal conditions. 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. 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. 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.

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. The LVA incorporates an aeroskirt to mitigate aerodynamic loads on the vehicle stack during launch, ensuring structural integrity under dynamic pressure conditions. This adapter also handles critical interfaces, including electrical connections, propellant umbilicals, and separation mechanisms for post-launch spacecraft deployment. Pre-launch integration occurs primarily at Kennedy Space Center's Space Launch Complex 41, beginning with the assembly of the in the Vertical Integration Facility (VIF). The process involves stacking the RD-180-powered first stage core with two AJ-60A solid rocket boosters (for crewed configurations like the N22 class), followed by mating the RL10-powered upper stage. 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 . 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. Once mated, the full vehicle—standing approximately 172 feet (52 meters) tall—is rolled out to the 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. This integration approach leverages the Atlas V's proven reliability, with over 90 launches since 2006, while adapting it for through enhanced abort system interfaces that allow the Starliner's to separate the crew module from the rocket in emergencies throughout ascent.

Nominal Mission Profile

The Boeing CST-100 Starliner spacecraft launches from Space Launch Complex 41 at , , aboard a 421 configuration rocket equipped with two solid rocket boosters and a upper stage. Following ignition of the '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 occurring at T+3:30 to T+4:00. The Starliner crew module separates from the 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. 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. 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. 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. Once docked, Starliner supports crew rotations of up to four astronauts plus for NASA-contracted ISS missions, with the remaining attached as a crewed safe haven capable of independent operation for up to seven days in contingency scenarios. 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 and data interfaces. 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. 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. Reentry involves peak heating at Mach 25, with the phenolic-impregnated carbon ablator managing temperatures up to 3,500°F; 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. Landing occurs at one of three primary sites in the —White Sands Space Harbor, ; Willcox Playa, ; or Dugway Proving Ground, —with weather criteria limiting winds to under 15 mph at surface level and visibility above 3 miles. 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.

Docking, Stay, and Undocking Procedures

The Boeing Starliner spacecraft employs the NASA Docking System (NDS) for autonomous docking to the (ISS), enabling independent connection without external aids such as robotic arms. 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. During the Crew Flight Test (CFT) on June 6, 2024, Starliner achieved soft capture at the forward port of the 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. Astronauts monitor the autonomous process but can intervene manually if anomalies occur, such as thruster performance issues observed pre-docking in the CFT mission. Once docked, Starliner remains attached to the ISS via the NDS mechanism, supporting transfer, power sharing, and data exchange through umbilical connections established post-hard capture. Nominal stay durations are planned for about , during which the conducts joint operations, including station familiarization, emergency drills, and scientific experiments, while the serves as a lifeboat. In the CFT, the stay extended significantly beyond the initial limit of 45 days due to concerns, including leaks and thruster malfunctions, enabling additional testing and research opportunities; the vehicle demonstrated capability for prolonged docking up to several months. 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 thrusters to achieve safe distance from the ISS. For the CFT, uncrewed undocking occurred on September 6, 2024, from the forward port, with the executing a deorbit burn leading to reentry and landing in roughly six hours later, validating the procedure sans crew. 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 by 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 , with an initial expectation of operational readiness by 2017. This timeline proved overly optimistic, as the program encountered repeated setbacks stemming from software anomalies, propulsion system failures, and integration challenges with the 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 reserves. Subsequent efforts to conduct a second uncrewed test (OFT-2) were indefinitely postponed in November 2021 amid discoveries of degraded propulsion valves and leaks, prompting to pivot resources toward the crewed (CFT) while addressing these issues through redesigns and extensive ground testing. The CFT, originally targeted for as early as , faced serial delays due to thruster malfunctions observed during hot-fire tests, system qualifications, and data recorder wiring concerns, ultimately launching on June 5, —nearly a decade after contract award and seven years behind the original schedule. Post-launch, 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 on September 6, , while the crew remained aboard the ISS until repatriation via Crew Dragon in March 2025. 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. 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. 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. 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. 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. 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.

Technical Failures and Safety Concerns

The Boeing CST-100 Starliner spacecraft has experienced recurrent propulsion system anomalies, including helium leaks and (RCS) thruster failures, during uncrewed and crewed test flights, prompting to prioritize safety over nominal return profiles. These issues stem from the service module's hydrazine-based thrusters, which rely on pressurized for flow, where seal degradation and potential overheating have compromised performance reliability. 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 (ISS) after a 48-hour delay. Post-mission analysis revealed helium leaks in the 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 valves, which had previously scrubbed a launch attempt in August 2021, further highlighting material durability challenges in the system's plumbing. The Crew Flight Test (CFT), launched uncrewed initially but crewed on June 5, 2024, with 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. and 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. Parachute system concerns compounded reentry risks, with pre-CFT reviews in June 2023 uncovering that "soft links" (fabric connectors) in the main risers failed to meet load-strength specifications under full-mass drop tests, alongside flammable wiring harnesses in the abort system violating standards. Although redesigns qualified all three drogue and main for crewed use—evidenced by the uncrewed CFT 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 connections, underscored iterative fixes needed for airbag-integrated touchdowns. 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. maintained adequate 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.

Management and Oversight Issues

Boeing's management of the Starliner program has been criticized for inadequate processes that failed to meet 's standards, with known deficiencies persisting despite contractual obligations. A 2024 NASA Office of report highlighted that Boeing's systems for tracking non-conformance issues and implementing corrective actions were incomplete, allowing problems such as thruster malfunctions and leaks during the Crew Flight Test (CFT) mission on June 5, 2024, to go unaddressed prior to launch. These lapses stemmed from Boeing's broader adoption of practices, which prioritized cost reduction over rigorous engineering oversight, resulting in rushed testing and overlooked integration issues between software and hardware. Whistleblower accounts have exposed a corporate culture at that discourages reporting of concerns, with employees facing retaliation for raising flags related to production. In 2024, Boeing space division workers filed lawsuits alleging isolation and reprisal for highlighting defects, reflecting a systemic undervaluation of employee input on and . 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 (ISS). 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. 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. During the CFT, cascading thruster failures and leaks—traced to degraded seals and blockages—highlighted ongoing gaps in joint anomaly resolution, with relying heavily on Boeing's internal assessments rather than independent validations. 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 from unmitigated technical risks and inefficient resource allocation. '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.

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 (ISS), both selected under the 2014 Commercial Crew Transportation Capability (CCtCap) contracts. allocated $4.2 billion to and $2.6 billion to for development, certification, and initial operational missions, reflecting an expectation of dual redundancy despite the cost disparity. '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. 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. Starliner, by comparison, suffered a software during its 2019 orbital , requiring a redo in 2022, and its June 5, 2024, Crew Flight Test (CFT) experienced multiple 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. As of October 2025, Starliner certification remains unresolved, with targeting an uncrewed post-certification flight no earlier than early 2026 pending propulsion and software fixes. 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 driven by milestones unmet and lower flight cadence. SpaceX's costs have adjusted upward to approximately $67-72 million per seat in extended contracts but benefit from through higher mission volume and reusability, with capsules like Endeavour completing multiple flights. 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 ports, and integrated launch abort systems—Starliner's using pyrotechnic separation with an rocket, versus Crew Dragon's integrated thrusters on Falcon 9. 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. 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.
AspectBoeing StarlinerSpaceX Crew Dragon
NASA Development Funding$4.2 billion$2.6 billion
First Crewed AttemptJune 2024 (docking failed)May 2020 (successful)
Crewed ISS Missions (Oct 2025)0>10
Est. Per-Seat Cost$90 million$55-72 million
Certification StatusPending (2026 target)Certified since 2020
These metrics illustrate Crew Dragon's edge in empirical performance, rooted in SpaceX's and flight-testing cadence, which enabled earlier risk retirement compared to Boeing's phased-gate methodology prone to integration surprises. No other direct U.S. competitors exist, though international options like Russia's Soyuz provide alternatives at higher per-seat costs (~$80 million) and geopolitical risks.

Future Prospects and Certification

Certification Process and Regulatory Hurdles

The certification of Boeing's CST-100 Starliner for operational crewed missions falls under NASA's , which requires contractors to demonstrate compliance with human-rating standards outlined in documents such as the Commercial Crew Transportation System Certification Requirements. These standards encompass end-to-end system verification, including abort capabilities, propulsion reliability, environmental controls, and autonomous docking, through a series of progressively complex tests culminating in a crewed (CFT). retains authority over final certification, evaluating data from ground tests, uncrewed orbital flights, and the CFT to ensure the vehicle meets safety thresholds for transporting astronauts to the (ISS), distinct from (FAA) oversight which primarily handles launch licensing via the 45th Space Wing. Starliner's certification path included the Pad Abort Test in November 2019, which validated launch escape performance, followed by Orbital Flight Test-1 (OFT-1) in December 2019 that aborted due to software errors preventing rendezvous, and a successful Orbital Flight Test-2 (OFT-2) in May 2022 that achieved docking and safe return. The CFT, launched on June 5, 2024, aboard a United Launch Alliance Atlas V, carried NASA astronauts Barry Wilmore and Butch Wilmore to the ISS but encountered helium leaks in the propulsion system and degradation or failure of five out of 28 reaction control system (RCS) thrusters during orbital maneuvers, raising concerns over return reliability. NASA deemed the risks unacceptable for crewed reentry, opting for an uncrewed Starliner return on September 7, 2024, while the astronauts remained on the ISS until their repatriation via SpaceX Crew-9 in February 2025; post-flight analysis attributed thruster issues to overheating and Teflon seal degradation, prompting extensive ground testing of over 70 anomalies identified since OFT-2. Regulatory hurdles persist as of October 2025, with requiring resolution of propulsion vulnerabilities—potentially necessitating a third uncrewed demonstration flight to rebuild confidence in RCS performance under prolonged firing conditions—before advancing to reviews targeted for late 2025 or early 2026. Budget constraints exacerbate delays, as Boeing's has exceeded $2 billion in overruns for development and fixes, straining resources amid parallel 737 MAX scrutiny, while schedule slippage to operational missions no earlier than mid-2026 risks ISS crew rotation gaps if unaddressed. Independent assessments, including Aerospace Safety Advisory Panel, highlight systemic engineering challenges at , such as inadequate pre-flight , underscoring the need for rigorous causal analysis of failure modes beyond superficial fixes to meet 's empirical safety benchmarks. Despite these obstacles, has affirmed intent to certify Starliner for redundancy against SpaceX's Crew Dragon, citing contractual obligations and strategic diversification, though critics argue over-reliance on risks taxpayer funds without proportional reliability gains.

Planned Operational Missions

The Boeing CST-100 Starliner program underwent a significant contract modification in November 2025 that adjusted planned missions to prioritize certification and safety. The next flight, designated Starliner-1, is now planned as an uncrewed cargo delivery to the International Space Station (ISS) no earlier than April 2026, rather than a crewed rotation as originally envisioned. This uncrewed mission aims to deliver cargo for station support and return via land landing in the American Southwest, providing additional data to support certification. NASA has assigned astronauts for the first crewed Starliner rotation flight, including NASA astronaut Scott Tingle as commander, NASA astronaut Mike Fincke as pilot, and Canadian Space Agency astronaut Joshua Kutryk as mission specialist, reflecting international partnerships under the . NASA has trained additional astronauts for potential backup roles, though assignments for subsequent missions remain unannounced pending Starliner-1 success and certification. Under the modified fixed-price contract with , the total number of flights has been reduced to four, including one uncrewed cargo flight and up to three crewed operational missions following certification, with each crewed flight capable of carrying up to four astronauts and 1,150 pounds of pressurized cargo. The contract value was reduced by $768 million to $3.732 billion to reflect these changes and focus on achieving certification. These missions would support crew rotation to the ISS through the remaining years of its operation, though actual scheduling depends on certification outcomes and vehicle reliability demonstrations. Delays in certification have prompted to adjust manifests, prioritizing flights in the interim while addresses thruster degradation and helium leak root causes through ground testing.

Long-Term Viability and Potential Cancellations

The Boeing Starliner program's long-term viability has been undermined by persistent technical anomalies and escalating financial losses, raising questions about its sustainability beyond initial efforts. Following the Crew Flight Test (CFT) launched on June 5, 2024, which encountered helium leaks and thruster malfunctions, opted to return astronauts Butch Wilmore and Suni Williams via in February 2025, while dispatching the uncrewed Starliner for reentry analysis on September 7, 2024. These issues, including degraded performance traced to overheating and valve failures, have delayed certification indefinitely, with assessing requirements for an additional demonstration flight as of March 2025. Boeing's internal reviews identified causal factors in manufacturing inconsistencies and software gaps, but root causes remain under investigation, eroding confidence in the spacecraft's reliability for routine operations. Financially, Boeing has absorbed over $2 billion in losses on the contract by February 2025, comprising $523 million in the latest quarter alone, driven by rework on propulsion systems and ground infrastructure upgrades at . Under the fixed-price agreement with —as modified in November 2025 to a value of $3.732 billion for reduced missions—Boeing bears all overruns, contrasting with SpaceX's , which achieved certification in 2020 with fewer delays and costs. This disparity has prompted scrutiny from 's Safety Advisory Panel, which in February 2025 highlighted a "new Boeing Starliner issue" involving structural vulnerabilities exposed during reentry data review, questioning the program's path to operational maturity amid Boeing's broader challenges, including setbacks. Despite these pressures, Boeing maintains commitment to resolving anomalies through thruster redesigns and enhanced testing protocols, targeting a post-certification flight no earlier than early 2026. The CCtCap contract incorporates standard Federal Acquisition Regulation (FAR) clauses, including the Termination for Convenience of the Government clause, allowing NASA to terminate at any time for any reason, with Boeing entitled to settlement costs for work performed, reasonable profit on completed efforts, and other allowable costs (no anticipatory profits). It also includes the Termination for Default clause, permitting NASA to terminate if Boeing fails to perform, potentially holding Boeing liable for excess reprocurement costs and other damages. No unique or specific penalties beyond these standard FAR provisions are detailed in public sources. In November 2025, the contract was modified to reduce missions and value (by $768 million to $3.732 billion), focusing on certification and safety. As of February 2026, despite ongoing issues and criticism, no termination has occurred. Potential cancellation remains a latent risk, though not actively pursued by as of February 2026, due to the agency's emphasis on provider redundancy for access amid Dragon's monopoly on crew rotations. Contractual obligations compel to complete required tests and missions, but failure to certify could trigger demands for another uncrewed test, further inflating costs estimated at hundreds of millions per iteration. Analysts note that with ISS decommissioning slated for 2030, Starliner's operational window is narrow—roughly five years—potentially rendering sunk investments uneconomical if reliability lags persist. 's strategic pivot toward collaborations and defense contracts may dilute focus, while 's options include sole-source extensions to or invoking termination clauses if safety thresholds are unmet, as deliberated in internal reviews post-CFT. No formal cancellation proceedings have been initiated, but ongoing viability hinges on demonstrating robust fixes in ground tests and a successful mission.

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