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In the heat of competition: Boeing is working to correct two serious design problems that cropped up during the construction of its Starliner manned capsule.
First the thing was weighing too much:
One issue involved the mass of the crew capsule, which outgrew the lift capability of the United Launch Alliance Atlas 5 rocket selected to put it into orbit. The CST-100 Starliner will ride an Atlas 5 rocket with two solid rocket boosters and a dual-engine Centaur upper stage, and although Boeing and ULA engineers considered adding a third strap-on motor to compensate for the capsule’s extra weight, managers now have the spacecraft back under its mass allowance, Ferguson said.
Second, the capsule has a shape problem:
Ferguson said Boeing has a model of the Atlas 5 rocket and CST-100 Starliner in a wind tunnel to verify a change to capsule’s outer shape devised to overcome higher-than-expected aerodynamic launch loads discovered in testing. “They had one issue, a non-linear aerodynamic loads issue, where they were getting some high acoustic loads right behind the spacecraft,” said Phil McAlister, head of NASA’s commercial spaceflight development office in Washington.
Something here is rotten. It seems to me that Boeing shouldn’t be having these very basic problems right off the bat. In the past, under the older cost-plus contracts NASA used to routinely hand out, these kinds of problems would simply have meant that Boeing would have gotten more money from NASA, This time, however the contract is fixed-price. If Boeing has problems or delays, the company will have to bear the cost, not NASA. I suspect these problems might have occurred because of some cultural laziness at Boeing. Their management is used to not having to eat the cost of these kinds of mistakes. Now, they will. I expect the culture to therefore begin changing.