Tag: Boeing

NASA announces launch coverage for the first Starliner manned capsule launch on May 6, 2024

10:23 am

NASA today released the details for its public media coverage of the first manned launch at 10:34 pm (Eastern) on May 6, 2024 of Boeing’s Starliner capsule.

NASA will provide live coverage of prelaunch and launch activities for the agency’s Boeing Crew Flight Test, which will carry NASA astronauts Butch Wilmore and Suni Williams to and from the International Space Station.

Launch of the ULA (United Launch Alliance) Atlas V rocket and Boeing Starliner spacecraft is targeted for 10:34 p.m. EDT Monday, May 6, from Space Launch Complex-41 at Cape Canaveral Space Force Station in Florida. The flight test will carry Wilmore and Williams to the space station for about a week to test the Starliner spacecraft and its subsystems before NASA certifies the transportation system for rotational missions to the orbiting laboratory for the agency’s Commercial Crew Program.

Starliner will dock to the forward-facing port of the station’s Harmony module at 12:48 a.m., Wednesday, May 8.

Though that coverage includes several prelaunch and post launch press conferences, the key coverage of the launch itself will begin at 6:30 pm (Eastern) on May 6th, about four hours before the launch itself. It will also include the capsule’s docking with ISS on May 8th.

I will embed NASA’s Youtube live stream here on Behind the Black on both dates, though as always I sugggest waiting until just before launch and docking to tune in. The four hours of streaming prior to launch is mostly going to be NASA propaganda, touting the agency and often misconstruing the facts to overstate its importance. This launch will be just like SpaceX’s Dragon launches, in that almost everything will be run by the two private companies involved, Boeing and ULA, and not NASA. NASA’s real involvement will only begin at the docking to ISS.

This first manned flight of Starliner is long past due. It was supposed to occur about four years ago, but numerous technological and management problems at Boeing forced many delays. Getting that capsule operational will finally give NASA two American companies capable of putting humans in space. It will also offer some competition to SpaceX, though this competition will be weak until Boeing can demonstrate Starliner’s reliability.

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Boeing to reduce staffing for SLS due to overall delays in Artemis

9:53 am

Boeing announced yesterday that it is going to reduce the staffing for its SLS rocket, caused by delays in other parts of the program that force it to stretch out operations.

When Boeing cites “external factors,” it is referring to the slipping timelines for NASA’s Artemis Program. In January officials with the space agency announced approximately one-year delays for both the Artemis II mission, a crewed lunar flyby, to September 2025; and Artemis III, a lunar landing, to September 2026. Neither of these schedules are set in stone, either. Further delays are possible for Artemis II, and likely for Artemis III if NASA sticks to the current mission plans.

Although the SLS rocket will be ready for the current schedule, barring a catastrophe, the other elements are in doubt. For Artemis II, NASA still has not cleared a heat shield issue with the Orion spacecraft. That must be resolved before the mission gets a green light to proceed next year. The challenges are even greater for Artemis III. For that mission NASA needs to have a lunar lander—which is being provided by SpaceX with its Starship vehicle—in addition to spacesuits provided by Axiom Space for the lunar surface. Both of these elements remain solidly in the development phase.

What Boeing is telling us indirectly is that, though NASA has not yet announced any further delays in those launch dates for Artemis-2 and Artemis-3, those dates are going to be delayed, quite possibly by one or more years.

None of this is a surprise. I have long been predicting that the first manned lunar landing in the Artemis program will not take place before 2030. In fact, that date was obvious the moment NASA announced its plan to make the Lunar Gateway space station an integral part of the program, back in 2018, when it was called LOP-G.

Now that SLS development is complete and NASA considers it “operational”, Boeing is merely reducing the staffing to maintain its assembly line, reducing it accordingly because of expected delays when additional rockets will be needed.

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First manned Starliner mission now targeting a May 6, 2024 launch

8:47 am

In order to work around scheduling issues at ISS, NASA and Boeing have now scheduled the first manned Starliner mission to launch no earlier than May 6, 2024.

Following a review of the International Space Station operations, NASA’s Boeing Crew Flight Test now is targeting no earlier than Monday, May 6, for Starliner’s first launch with astronauts to the orbital complex. The date adjustment optimizes space station schedule of activities planned toward the end of April, including a cargo spacecraft undocking and a crew spacecraft port relocation required for Starliner docking. NASA and Boeing also are performing prelaunch closeout work and completing final certification for flight.

Two astronauts will fly the capsule to ISS for a two week stay, testing its systems in order to determine if it is ready for regular operations.

This launch is years behind schedule due to numerous technical problems that have cost Boeing billions in extra costs as well as lost income. In order to convince other customers besides NASA to buy seats on Starliner will likely require the capsule to fly many times without issues. Until then, I suspect anyone wishing to do a tourist flight in space will pick SpaceX instead, because of its now proven safety and reliability record.

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Boeing’s problems are only the tip of the iceberg

1:25 pm

Most of all beware this boy.’
As noted by the Spirit of Christmas Present in Dickens’ The Christmas
Carol, ‘This boy is ignorance, this girl is want. Beware them both,
but most of all beware this boy.’

Since the beginning of this year, following the near disaster when a door of a Boeing 737-Max airline blew off during the Alaska Airlines flight, the media has been obsessed with reporting every single subsequent Boeing airplane incident as attributed to bad management and quality control at Boeing.

The problem with this shallow reporting is that it fails entirely in recognizing the real depth of the problem.

First, in most of the incidents reported, the planes involved were not recent purchases from Boeing, but had been owned by the airlines for years, sometimes decades. Thus, any maintenance issues, such as a wheel falling off after take-off or a landing gear collapsing on landing or the sudden failure of an Airbus plane’s hydraulic system, are not Boeing’s fault, but the fault of the airline the plane belongs to. In the case of these particular incidents, that airline was United, and in every case, the failure was with its maintenance department, not Boeing’s bad management and poor quality control.

A similar string of incidents has also occurred at American Airlines, involving both Boeing and Airbus airplanes. With both United and American, evidence suggests that the quality of its maintenance staff has likely declined significantly since 2020, when both companies decided to abopt Diversity, Equity, and Inclusion (DEI) hiring practices, which made skin color and sex the most important qualification in hiring, rather than talent, skill, experience, or knowledge.

It is important for readers to recognize this fact when they see new stories about a Boeing plane forced to make an emergency landing, such as the story today about a United Airlines’ Boeing 787. It apparently had a cracked windshield, requiring an unscheduled landing in Chicago. The article at the link focuses a great deal on Boeing, but the focus should instead be on United Airlines, not the airplane maker, since it is United’s responsibility to keep its fleet flightworthy. When an airline fails to do so, future customers should take note, and consider other options when they need to fly.

In other words, you shouldn’t avoid flying on a Boeing plane, you should avoid flying on airlines that maintain their airplanes badly.

Having said this, I don’t want my readers to think I am trying to let Boeing off the hook. Far from it. » Read more

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The DEI disaster now appears to be hitting American Airlines

2:54 pm

American Airlines; Clowns in charge!

The continuing and almost daily airline incidents in recent weeks, with planes repeatedly being forced to make emergency landings because of mechanical failures, has too often been blamed by the media on Boeing and the airplanes it builds, when almost all of these mechanical problems have had nothing to do with that airplane manufacturer. Once Boeing sells a plane to an airline, it becomes the airline’s responsibility to maintain it and keep it airworthy. Boeing itself might have serious management and quality control problems making its new planes suspect, but when older planes fail it is not Boeing’s fault. For example, all of the recent failures at United were clearly due to failures of United’s own maintenance staff, failures quite likely instigated by that company’s decision since 2020 to make race and gender the primary qualifications for hiring, not skill, talent, or knowledge.

We are now seeing the same phenomenon at American Airlines (AA), which since December has experienced its own string of flight emergencies:
» Read more

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Another United airplane makes an emergency landing

1:26 pm

United Airlines: Run by bigoted clowns
United Airlines: Run by bigoted clowns

As more proof that the United Airlines policies for hiring and promotion — focused solely on skin color, ethnicity, and sex more than talent, knowledge, and skills — is making flying on that airline downright dangerous, another United flight today had to make an emergency landing when immediately after take-off fluid began pouring from the plane.

Just 10 seconds after flight 830 from Sydney to San Francisco took the air, video by plane spotter New York Aviation got clear images of fluid spewing from the plane — it looks like it was coming from the rear right landing gear.

The crew of the Boeing 777-300 jet continued over the ocean for a while before turning around. Video from a passenger shows the crew dumping fuel before landing. The plane landed safely back at the airport in Sydney, with no injuries, but a lot of questions.

This was the fifth such incident of a United flight in just over a week, including four emergency landings and a failure after landing.

Though this was a Boeing jet, the fault here lies entirely with United, its pilots, and its maintenance department. Though pilots should be able to rely on their maintenance departments to keep the plane airworthy, they are also supposed to check their airplanes carefully before take-off. That neither the pilots of this plane or the maintenance staff detected anything before take-off suggests that no one is really doing their job right.

No matter. United is determined to make sure that half its employees are blacks or minorities or women, no matter how little those new hires know about maintaining an airplane. So what if planes fall from the sky and people die? United will have achieved diversity, equity, and inclusion!

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United Airlines diversity quotas finally begin paying off in disaster

11:57 am

United Airlines: Run by fascist clowns
United Airlines: Run by fascist clowns

In the past week there have been four serious airplane incidents involving United Airlines. Though most of the media focus has been aimed at Boeing — which clearly has demonstrated significant management and design issues with almost all its new products in the past few years — the real culprit of these recent failures is not Boeing. All of the following potentially deadly incidents occurred on United flights, and all suggest major problems within its maintenance and hiring departments.

  • March 4: A United Boeing 737 had to make an emergency landing shortly after take-off when a fire started in one of its engines. One news report claimed the fire was caused when some bubble wrap was pulled into the engine, an explanation that seems exceedingly unconvincing, especially because no investigation has yet been completed.
  • March 7: While taking off in San Francisco, one wheel on a United Boeing 777-200 airplane fell off, crushing several cars in an airport employee parking lot, with the plane making an emergency landing in Los Angeles. United had purchased the airplane 22 years previously, so the problem had to come from within United’s maintenance department.
  • March 8: A United Boeing 737-Max ended up on the grass while taxiing off the runway after landing when its left main landing gear collapsed. One passenger reported the incident occurred due to bad driving by the pilot, who mistakenly steered the plane onto the grass, causing the gear to collapse.
  • March 8: A United Airbus A320 had to make an emergency landing in Los Angeles when it experienced “complete hydraulic failure” in one of the airplane’s three hydraulic systems.

In 2020, shortly after George Floyd’s death, United officials made a very public commitment to instituting Diversity, Equity, and Inclusion (DEI) quotas in hiring, from maintenance to pilots. For example, it announced it would favor training and hiring pilots based on skin color and sex, regardless of qualification.
» Read more

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First manned Starliner mission slips to May

8:53 am

The first manned mission of Boeing’s Starliner capsule has now been delayed another few weeks, to early May, due to scheduling conflicts at ISS.

The delay was revealed as an aside in a NASA press release detailing the schedule of press briefings related to the mission. There appears to be no technical reasons for the delay. The quiet way NASA revealed it probably just indicates the agency’s embarrassment at Boeing’s overall problems with this spacecraft that have caused a four year delay in its first manned mission.

The flight will dock with ISS, last two weeks, and carry two astronauts, Butch Wilmore and Suni Williams. Its goal is to complete the final check out of Starliner prior to the initiation of operational missions. Once done, Boeing will not only begin to fly paid flights to ISS for NASA, it will be free to offer this capsule to others, including commercial tourists. Don’t expect customers to flock to buy seats, considering the many problems both Boeing and Starliner have had. Instead, it will likely take Boeing several years of NASA missions to reassure customers the spacecraft is reliable.

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ULA begins stacking Atlas-5 rocket for launching the first manned mission of Starliner

9:26 am

ULA has begun to assemble the Atlas-5 rocket that will hopefully launch Boeing’s Starliner capsule on its first manned mission to ISS, presently targeting a late April lift-off.

The rocket’s main stage was transferred from the nearby Advanced Spaceflight Operations Center to the integration facility Wednesday, Feb. 21, where it will await integration with the rocket’s upper Centaur stage and Starliner. The spacecraft will carry NASA astronauts Suni Williams and Butch Wilmore to the orbiting laboratory for a short stay of about one to two weeks before returning to a landing site in the southwest United States.

The late April date appears to be a slight delay from previous announcements.

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Lockheed Martin & Boeing get Space Force satellite development contracts

9:43 am

The Space Force has awarded Lockheed Martin and Boeing $66 million contracts each to design their own version of a new communications satellite for the military.

Over the next 15 months, the companies will create prototype satellites showing how they would meet the Space Force’s requirements for the MUOS satellites. DoD announced the contract awards Jan. 25.

The Space Force is expected to select one of the companies in 2025 to manufacture two flight-ready narrowband satellites to modernize the existing constellation of five MUOS satellites in geosynchronous orbit. Narrowband communications use relatively small amounts of data, but are critical for military operations.

A third unnamed company also bid but was not selected. The choice of Boeing for this competition is surprising, considering its numerous management and engineering problems across a wide range of products, from airplanes to space capsules. NASA itself has been so dissatisfied with Boeing’s work that in 2020 it decided at that time “to eliminate Boeing from future award consideration.” That decision appears to still stand. As far as I can remember Boeing not won any NASA contracts since.

Moreover, Lockheed Martin built the current MUOS satellites in orbit, while Boeing does not have a big reputation in recent years building satellites.

All told, it will therefore be extremely surprising if Boeing wins this competition. I suspect the Space Force issued this contract to help keep Boeing a viable company and to give it an opportunity to get its act together. Rewarding incompetence however is rarely successful.

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Starliner launch in mid-April continues on target

10:35 am

In an update today from NASA, it appears the first manned flight of Boeing’s manned Starliner capsule remains on target for a mid-April launch on a ULA Atlas-5 rocket.

Engineers continue to analyze the data from the recent parachute drop test that appeared to prove out the redesign of the capsule’s parachutes. Also, the work to replace or mitigate the flammable tape in the capsule has been completed.

Boeing completed removal of P213 tape that may have posed a flammability risk in certain environmental conditions. Boeing removed more than 17 pounds, or roughly 4,300 feet, of the material from the Starliner crew module. For areas in which removal of the tape carried an increased risk to Starliner hardware, Boeing applied tested remediation techniques such as overwrapping the P213 tape with another non-flammable, chafe-resistant tape, and installing fire breaks on wire harnesses.

No explanation as yet has been released as to how it was even possible for Boeing to have used this tape, considering it has been common practice since the Apollo 1 fire in 1967 to avoid the use of flammable materials in spacecraft. Nor has any explanation been issued on how the weak link in the main parachute connection to the capsule was not discovered until only weeks before the manned flight, last summer.

Nonetheless, both issues appear solved. After years of delays and innumerable problems, Boeing might finally be ready to fly Starliner with passengers. It desperately needs this flight to be successful, especially considering the company’s other ongoing problems with its 737 airplane. It also will not receive the rest of its contract payments from NASA until this flight is a success, and the delays and problems have cost the company more than $1.5 billion. The contract was fixed price, so Boeing has had to pay for all the additional costs from its own pocket.

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Boeing completes Starliner parachute drop test

9:13 am

Boeing on January 9, 2023 successfully completed a parachute drop test of its Starliner capsule, testing whether the redesigned connection between the chutes and the capsule was now meeting proper safety specifications.

The drop test, which used a Starliner parachute system attached to a dart-shaped sled the same weight as a Starliner, was performed to confirm the functioning of a redesigned and strengthened soft link joint that is part of the network of lines connecting the parachutes to the spacecraft. The test also validated a change to strengthen one textile joint in the parachute, increasing overall parachute robustness. As with other capsules, Starliner relies on parachutes to land safely when it returns to Earth.

Engineers are still analyzing the results, though the parachutes worked as planned. The first manned mission of Boeing’s commercial capsule is now scheduled for April 2024, only four years late as well as four years after SpaceX accomplished the same thing. It still remains staggering that the company did not find out about that soft link joint when it was designing the capsule, instead of only months before the first manned mission last year. It is not as if the use of parachutes to land capsules is cutting edge technology.

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Boeing dropped from competition for Air Force “doomsday” plane

6:09 pm

It appears that by mutual agreement the Air Force has eliminated Boeing in the competition to build a new replacement for the E-4B Nightwatch, what the military calls its “doomsday” airplane, designed to survive a nuclear war.

Sources told Reuters that Boeing – the incumbent manufacturer of the E-4B Nightwatch – could not agree with the USAF on data rights and contract terms for the replacement plane that began flying in the 1970s. In other words, the planemaker did not want to sign a fixed-price agreement.

…”Rest assured, we haven’t signed any fixed-price development contracts nor (do we) intend to,” Brian West, Boeing’s chief financial officer, told investors in October.

With Boeing out of the competition, Sierra Nevada (the parent company of Sierra Space) is left as the only bidder. It is also quite willing to operate under a fixed price contract.

As I noted in a comment thread after a reader first posted a link to this story,

Boeing is signing its own death warrant. The entire federal defense and space agencies are steadily switching to fixed-price, and will simply go to others if Boeing refuses to accept those terms.

In fact, those agencies will want to go to others, because Boeing is making it clear it can’t meet its contractual obligations.

This decision also tells us a great deal about Boeing as a company. Its inability to fulfill any contract under a fixed price means it no longer has the discipline to do anything right. It seems buying products from it at this point might be a very foolish proposition.

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Boeing losses total almost a billion dollars this quarter

1:15 pm

The hits to Boeing keep coming: In addition to the $1.5 billion it has had to write-off because of problems with its Starliner capsule, Boeing is now reporting losses in the third quarter totaling almost a billion dollars, with half those losses coming from overruns on its fixed price contract to provide Air Force One to the U.S. government.

The $482 million loss on the high-profile presidential plane was due to “higher estimated manufacturing costs related to engineering changes, labor instability and the resolution of supplier negotiations,” Boeing Chief Financial Officer Brian West said during the company’s third-quarter earnings call Wednesday.

Boeing has faced numerous problems with the VC-25B program, including shortages of workers and parts, that have delayed delivery of the first of two Air Force One jets until 2027. To date, the company has lost over $2.4 billion on the program, according to a company spokesperson. CEO Dave Calhoun said last year that Boeing should have never agreed to the fixed $3.9 billion price tag.

The second-largest contributor to losses for Boeing’s Defense, Space & Security (BDS) business was a satellite program that cost the company $315 million in the third quarter. The company wouldn’t identify the program, but West said the loss is “tied to customer considerations and higher estimated cost to deliver a highly innovative satellite constellation contract that we signed several years ago.” [emphasis mine]

Let me translate what CEO Calhoun was really saying in the highlighted sentence: “We want a blank check! Boeing is incapable of producing anything based upon a standard fixed price, and wants the federal government to go back to open-ended cost-plus contracts that put no limit to overruns and schedule delays.”

Whether Boeing gets that blank check or not really depends on Boeing. It is very possible our corrupt legislators in Congress — who think money grows on trees — will bring these cost-plus contract back, but I doubt Boeing will win many such contracts in the near future, based on its horrible performance on all levels technically. It needs to completely clean house, with major shake-ups in management and staff, as whoever is working there now is simply doing a terrible job.

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First manned Starliner mission now delayed to April 2024

8:45 am

In a press release yesterday that outlined the updates to NASA’s scheduled manned missions to ISS, the agency confirmed that the first manned Starliner mission has now been delayed one more month, from March until April 2024.

The first crewed flight of the Starliner spacecraft, named NASA’s Boeing Crew Flight Test (CFT), is planned for no earlier than mid-April. CFT will send NASA astronauts and test pilots Butch Wilmore and Suni Williams on a demonstration flight to prove the end-to-end capabilities of the Starliner system. Starliner will launch atop a United Launch Alliance Atlas V rocket from Cape Canaveral Space Force Station in Florida, spend approximately eight days docked to the space station, and return to Earth with a parachute and airbag-assisted ground landing in the desert of the western United States. [emphasis mine]

The highlighted words underline the fact that this date is merely a target, and has been announced as part of the entire schedule for all the manned missions to ISS next year, fitting it in between two SpaceX crewed Dragon flights. It assumes Boeing will have the spacecraft ready by then, but based on that company’s track record, that assumption remains dangerous. Boeing has a lot of work to do, including parachute drop tests to fix the parachute cords as well as replacing the flammable electric tape installed throughout the capsule.

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Boeing delays first manned Starliner flight again, until March of 2024

4:21 pm

Because of both parachute and wiring issues in its Starliner capsule, Boeing revealed today that it is delaying the first manned Starliner flight again, until March of 2024, so that it has time to change and test the parachutes as well as remove the flammable tape inside the capsule.

The company had been hoping to finally fly that first manned flight last month, but was forced to cancel when in June it discovered two shocking problems. First the connections between the parachutes and the capsule were too weak, and second, for some reason engineers had used tape to protect the capsule’s wiring that was too flammable and had to be replaced or covered somehow.

Boeing is taking the tape off in places where it’s easy and safe to do so and considering other remediation techniques, such as protective barriers or coatings over it, in trickier spots, Nappi said.

The parachute work is multifaceted as well. For example, Boeing has modified the soft link design to make it stronger, and the new version is being manufactured now, Nappi said. The company also decided to swap out Starliner’s parachute system, putting a new version slated for the first operational mission on board for [the crew flight test]. The new soft links will be incorporated into the new chutes, which will get to strut their stuff during a drop test soon. “We expect that the drop test will occur in mid to late November,” Nappi said. “That’s what the planning indicates at this point, and we’ll watch that closely.”

The seemingly endless number of mistakes and bad engineering that we have seen during the development of Starliner speaks very badly of Boeing in almost every way possible. These last two problems are especially egregious. Neither should have ever happened, and if so should never had been unnoticed until a mere month before launch and years into the project.

It must also be noted that March ’24 is merely a target date. Don’t bet the house on it happening then.

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Boeing’s total losses due to Starliner now equal $1.5 billion

9:44 am

According to CNBC, the total losses for Boeing due to its on-going and persistent engineering problems flying its manned Starliner capsule now equal almost $1.5 billion, not $1.1 billion as estimated yesterday.

Since 2014, when NASA awarded Boeing with a nearly $5 billion fixed-price contract to develop Starliner, the company has recorded losses on the program almost every year. The charges total $1.47 billion, according to its annual reports and the company’s most recent quarterly filing.

The annual losses have ranged from $57 million in 2018 to $489 million in 2019.

At this moment, the only way Boeing can make a profit on Starliner is to garner a lot of other tourist customers, outside NASA. The problem is that SpaceX’s already operational fleet of four manned Dragon capsules has captured that market, with a capsule and rocket that has demonstrated remarkable reliability. To convince others to fly on Starliner it will have to fly it a lot beforehand in order to convince others its problems have really been fixed. This will take time and money, which will only add to the red ink.

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Boeing gets NASA contract to develop new airplane wing design

10:22 am

In its effort to reduce fossil fuel use and thus save us from being burned to death by global warming in only a decade, NASA has now awarded Boeing a contract to develop new airplane wing design that it predicts will lower fuel use by up to 30%.

The X-66A is the X-plane specifically aimed at helping the United States achieve the goal of net-zero greenhouse gas emissions by 2050. To build the X-66A, Boeing will work with NASA to modify an MD-90 aircraft, shortening the fuselage and replacing its wings and engines. The resulting demonstrator aircraft will have long, thin wings with engines mounted underneath and a set of aerodynamic trusses for support. The design, which Boeing submitted for NASA’s Sustainable Flight Demonstrator project, is known as a Transonic Truss-Braced Wing.

While developing a more efficient wing design is certainly worthwhile, having skepticism about this project is certainly reasonable. First of all, it seems somewhat strange to award Boeing such a contract at this time, considering NASA own experience with the company with Starliner, as well as that company’s problems with other government contracts for the military.

Secondly, the press release makes a big deal about the project getting an X-plane designation, an entirely superficial and PR related title that if anything suggests there is very little steak to this sizzle.

Third, it is unclear the nature of this contract. Is is cost-plus, or fixed price? The press release says NASA will “invest $425 million over seven years, while the company and its partners will contribute the remainder of the funding, estimated at about $725 million.” If cost-plus, this means nothing. Boeing will use any excuse to go over budget in order to get more money from NASA.

Finally, half a billion dollars to develop and test a new airplane wing design, using an already existing airplane, seems incredibly exorbitant. And to require seven years to build it seems ridiculously long.

All in all, I suspect the real goal of this project is to funnel tax dollars to Boeing to help keep it afloat, not to build a new green airplane.

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Boeing sued for stealing specialized tooling to assembly SLS

9:36 am

A Colorado company, Wilson Aerospace, on June 6, 2023 filed a lawsuit against Boeing, claiming that the company conspired with Wilson’s direct competitors to steal the designs of its specialized tool for installing the core station engines on SLS.

According to the lawsuit, after some initial discussions, Boeing arranged for a “live” demonstration of Wilson’s torque device, during which participants could handle and operate it to verify the tool’s capability and performance. What Wilson claims it did not realize, however, is that some of the participants in this demonstration were not Boeing employees. “Wilson later learned that at least seven of those in attendance for the live presentation were external to Boeing and were, at the time, employees of Wilson’s direct competitors,” the lawsuit states. “This fact was concealed from Wilson who was deceived by Boeing and the ‘Bogus Boeing Employees’ into giving the presentation by falsely suggesting to Wilson that everyone was a Boeing employee.”

The complaint alleges that Boeing subsequently used information from this demonstration, as well as proprietary drawings and designs, to work with Wilson’s competitors to develop a cheaper solution. “Boeing concealed these facts from Wilson as part of its scheme to defraud Wilson and to transmit Wilson’s IP to its direct competitors,” the lawsuit states.

The company is demanding a jury trial. If its charges are proved true, it will be another piece of evidence demonstrating the level of corruption that exists at Boeing.

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Newly discovered Starliner issues delay launch again

9:24 am

NASA and Boeing revealed today that two newly discovered design issues involving Starliner’s parachutes and the tape used to protect the capsule’s wiring has forced it to cancel the planned June launch, with no firm new launch date scheduled.

The parachute issue involves the parachute cords, specifically the “soft link joints” that connect those lines to the capsule.

[Mark Nappi, Boeing’s Starliner VP] told reporters fabric links that join the parachutes to the lines of the spacecraft, called soft link joints, need to be replaced and possibly recertified to withstand heavier loads and stresses to ensure crew safety. “They were tested recently because of a discovery that we found during the review process where we believed that the data was recorded incorrectly,” Nappi said. “We tested (the soft links), and sure enough, they did fail at the lower limit.” [emphasis mine]

The tape — which has been found to be far more flammable than expected — is difficult to fix.

The second problem found last week is more extensive since the tape used to protect Starliner’s wiring harnesses from nicks or abrasions runs for hundreds of feet through several of the spacecraft’s internal systems. “There is a lot of tape on the wire harnesses,” Nappi said. “We’re looking at solutions that would provide for potentially another type of wrapping over the existing tape in the most vulnerable areas that reduces the risk of a fire hazard.”

That both of these issues were not fixed in development is beyond astonishing and speaks so badly of Boeing’s engineering and management that it is difficult to find words. In fact, for Boeing to use tape that could cause a fire now, more than a half century after the Apollo 1 capsule fire, suggests a level of incompetence that makes one wonder why anyone would ever fly on any of its spacecraft or airplanes. This is certainly not the company that built the 747.

Officials indicated that they might be able fix this issues fast enough that a fall launch could occur, but made no promises.

For Boeing, this new delay only worsens its bottom line. It built Starliner on a fixed-price contract, so every delay and issue must be paid for by it, not NASA. Meanwhile, the delays mean that SpaceX is getting flight contracts to ISS from NASA, contracts that Boeing would have gotten had Starliner been ready as planned. Worse, ISS is now looking at a 2028 retirement. If Boeing doesn’t get Starliner operational soon, there might not even be any contracts for it to win.

I have embedded the full press conference below for those who wish to watch NASA and Boeing officials blather about how they really haven’t done anything stupid here. Really, you have got to believe them!
» Read more

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NASA’s corrupt safety panel doubts Starliner is ready for its first manned flight in July

9:26 am

The head of NASA’s safety panel — which over the years has consistently missed the big safety issues while whining about things that did not matter — expressed strong doubts yesterday on whether Boeing’s Starliner manned capsule is ready for its first manned flight in July.

Speaking at a May 25 public meeting of the Aerospace Safety Advisory Panel, Patricia Sanders, chair of the committee, expressed skepticism that NASA and Boeing will be able to close known issues with Starliner in time for a launch currently scheduled for as soon as July 21.

“There remains a long line of NASA processes still ahead to determine launch readiness” for the Crew Flight Test (CFT) mission, the first crewed flight of the spacecraft with two NASA astronauts on board. “That should not be flown until safety risks can either be mitigated or accepted, eyes wide open, with an appropriately compelling technical rationale.”

This panel hasn’t the faintest idea what it is talking about, and should be ignored. It appears that NASA and Boeing are presently reviewing the capsule’s parachute system. Sanders however raised other issues which actually appear more designed to simply slow or even prevent the capsule’s launch.

The panel did the same thing during the development of SpaceX’s manned Dragon capsule, making irrelevant claims about paperwork and the safety of the company’s Falcon 9 fueling procedures that were ridiculous. Meanwhile, it has ignored much more fundamental numerous safety issues with NASA’s SLS rocket and Orion capsule, such as the agency’s plan to fly it manned using its capsule environmental system for the first time.

It is very possible that there remain serious safety issues with Starliner. I simply note that I would not rely on NASA’s safety panel to provide me an honest or educated appraisal of the situation.

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Boeing & NASA; 1st Starliner manned mission to now launch on July 21

3:34 pm

In a update posted by NASA today, agency and Boeing officials announced that they are now aiming to launch Boeing’s Starliner capsule on July 21, 2023 on its first manned mission to ISS.

The new target date provides NASA and Boeing the necessary time to complete subsystem verification testing and close out test flight certification products and aligns with the space station manifest and range launch opportunities.

The specifics behind this somewhat meaningless press release jargon can be found at this twitter thread. Apparently Boeing & NASA want to do more ground tests of the capsule’s parachute system as well as its flight software. There also appears to be some issue relating to the capsule’s batteries.

Boeing is also mulling a redesign of Starliner’s batteries for after this delayed crewed flight test. It also expects to redesign Starliner’s smart initiator system, which separates the crew from service module. NASA’s paying $24 million for that redesign amid added requirements

Though Boeing has a fixed price contract with NASA, if NASA demands redesigns or changes it has to pay for them. That Boeing and NASA are finding these issues at this late date, four years after Starliner was first supposed to launch, does not speak well of Boeing’s workmanship and quality control systems.

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Starliner’s first manned mission to ISS delayed again

9:36 am

According to a tweet by a NASA official, the first manned mission to ISS of Boeing’s Starliner capsule, carrying two NASA astronauts, has been delayed again, from the planned late April launch to sometime during the summer.

No reasons for the delay were given, as yet. The second link notes however that a schedule conflict at ULA, which is launching Starliner on its Atlas-5 rocket, might be part of the reason.

A launch in late April [of Starliner on the Atlas-5] would have put it in conflict with the inaugural launch of United Launch Alliance’s Vulcan Centaur rocket, currently scheduled for as soon as May 4. Vulcan and Atlas use the same launch pad at Cape Canaveral Space Force Station, and ULA has been conducting tests of the Vulcan rocket on that pad. It has not shared updates on the status of the Atlas 5 used for Starliner.

This conflict might also explain why Starliner itself has not yet been fueled, since Boeing officials have said they want to do this within 60 days of launch to avoid the same kind of valve leaks that delayed the second unmanned demo mission for almost a year.

Starliner itself is years behind schedule, a long delay that has cost Boeing an enormous amount of income. First, the problems during the first unmanned demo flight in December 2019 forced the company to do a second unmanned demo flight, on its own dime costing about $400 million. That second flight was then delayed because of those valve issues. All the delays next cost Boeing income from NASA, as the agency was forced to purchase many manned flights from SpaceX that it had intended to buy from Boeing.

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A review of Boeing’s struggling space effort

8:53 am

Link here. [now fixed] The article, entitled “As Boeing Struggles To Fix Its Airliner Business, Elon Musk Is Eating Its Lunch In Space,” is a remarkably accurate overview of Boeing’s space effort, considering it comes from a mainstream press outlet. This paragraph will give you its flavor:

New competition could also threaten Boeing’s lucrative Space Launch System. Nicknamed the “Senate Launch System” for its origins in 2010 as a pork-barrel program to preserve jobs with the Space Shuttle winding down, NASA procured the rocket with “cost-plus” contracts – totaling $13.8 billion for Boeing so far – which means the contractor is guaranteed its expenses will be covered, plus a profit. Critics say that’s encouraged cost overruns. NASA’s inspector general has pegged the cost of a single Artemis launch at $4.1 billion, which he characterized last year as “unsustainable,” with total spending on the program projected to top $90 billion by 2025. For reference, NASA’s budget this year is $25 billion.

“This is a sucking chest wound on NASA and their ability to actually advance planetary science and lunar programs,” said Chris Quilty, founder of the space -focused financial services firm Quilty Analytics.

That $13.8 billion figure is accurate as to what NASA has paid Boeing, though it underestimates the actual cost of SLS, which is more than twice that.

Read it all. It suggests Boeing faces very tough times ahead in space.

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NASA, Boeing, and the UAE negotiating partnership for building Lunar Gateway airlock

9:26 am

According to press reports in the United Arab Emirates (UAE), that country is negotiating with NASA and Boeing on a partnership to build an airlock module for NASA’s Lunar Gateway Moon space station.

US aerospace company Boeing said it has held discussions with Emirates officials about the UAE providing an airlock module on the Lunar Gateway. This is an airtight room that astronauts would use to enter and exit the space station.

John Mulholland, vice president and International Space Station programme manager at Boeing, told The National that the company was “actively working” with the UAE on the concept and design.

It appears the UAE is offering to pay Boeing to build it for NASA, and would expect in exchange a larger share in the use of the station.

If this deal works out, the UAE will essentially replace Russia as a Gateway partner. Russia had signed an agreement with NASA in 2017 to build that airlock, but that deal is now null and void following the Russian invasion of the Ukraine and its desire to partner with China instead.

For the U.S., this is a win-win, since it will now be an American company building the airlock, not Russia.

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NASA extends Boeing’s contract to produce more SLS rockets

10:30 am

NASA yesterday announced that it will pay Boeing $3.2 billion for two more SLS rockets.

NASA has finalized its contract with Boeing of Huntsville, Alabama, for approximately $3.2 billion to continue manufacturing core and upper stages for future Space Launch System (SLS) rockets for Artemis missions to the Moon and beyond.

Under the SLS Stages Production and Evolution Contract action, Boeing will produce SLS core stages for Artemis III and IV, procure critical and long-lead material for the core stages for Artemis V and VI, provide the exploration upper stages (EUS) for Artemis V and VI, as well as tooling and related support and engineering services.

All this really means is that NASA is going depend on SLS and Orion to fly its astronauts to and from the Moon, and because of that its pace of flight will be — at best — slow and long-drawn out. For example, this new order extends the contract out to 2028. It will thus leave plenty of time for SpaceX and other nations to get there first.

I predict that the private Starship missions paid for by Yusaku Maezawa and Jared Isaacman will both fly before these two new Artemis missions. You heard it here first.

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Last 747 rolls off assembly line

8:58 am

Boeing earlier this week completed assembly of its very last 747 airplane, the 1,574th such plane built in the past half century.

Still in its iridescent green protective coating, the giant aircraft was towed out of the widebody aircraft factory in a low-key exercise without any fanfare. Once the 747 has been cleared, it will be flown to another Boeing facility where it will be painted in the Atlas Air livery in anticipation of final delivery to the customer next year.

The 747 was born out of a failed bid by Boeing to market a large jet transporter to the US military in the 1960s. That contract for what became the C-5A Galaxy eventually went to Lockheed, but Boeing was convinced that its basic design, with its high-bypass turbofan engine, could be reworked for the civilian market, which was booming at the time.

On January 9, 1969, the first 747 prototype took to the skies over Washington state. It was a staggering 225 feet (68.5 m) long, had a wing area larger than a basketball court, and the tail was as high as a six-story building.

Without question the 747 was one of the safest and well designed airplanes ever built. It was years after that first flight before one was involved in an accident, and that was not due to a failure of the plane itself. It also flew like a dream, its large size making it look like it was lumbering slowly in the air. Its retirement is almost entirely related to fuel cost-savings, since the 747 has four engines and thus more fuel than more modern planes.

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Blue Origin-led team bids for NASA manned lunar lander contract

11:09 am

Capitalism in space: Though few details have been released, Blue Origin has teamed up with Boeing and Lockheed Martin to bid for a NASA contract to build a second manned lunar lander, after SpaceX’s Starship.

Blue Origin revealed its team’s submission to that second NASA program in a brief statement posted on its website on Tuesday, saying “in partnership with NASA, this team will achieve sustained presence on the Moon.”

The deadline for proposals was Tuesday. NASA is expected to make an award decision in June 2023.

Blue Origin’s team also includes spacecraft software firm Draper, Pittsburgh, Pennsylvania-based Astrobotic and Honeybee Robotics, a manufacturer of military and civil robotic systems that was acquired by Blue Origin in January.

It will be interesting to see if this proposed lander is significantly different than the previous proposal, which NASA considered overpriced and not as capable as Starship.

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Boeing announces major reorganization

9:33 am

Boeing yesterday announced that it is doing a major reorganization of its defense, space, and security divisions.

The action will replace numerous executives while reducing eight different divisions into four.

Such action was long overdue, considering Boeing’s many recent engineering failures, from space (Starliner) to aviation (737-Max), all of which demanded such a reorganization and consolidation, simply to pay the bills if not to fix serious management shortcomings. The bad economy has only made this more urgent.

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X-37B returns successfully to Earth after 908 days in orbit

7:13 pm

One of the two X-37B reusable mini-shuttles that Boeing built for the military successfully returned to Earth early this morning after completing 908 days in orbit, a new longevity record.

This was the sixth mission of the crewless reusable plane, built by Boeing and jointly operated by the U.S. Space Force and the Air Force Rapid Capabilities Office. Known as Orbital Test Vehicle 6, it launched to orbit May 17, 2020, on a United Launch Alliance Atlas 5 rocket.

On this mission the X-37B carried several U.S. military and NASA science experiments, including a Naval Research Laboratory project to capture sunlight and convert it into direct current electrical energy, and the U.S. Air Force Academy’s FalconSat-8, which remains in orbit.

It appears, based on the amount of information released after landing, that the Space Force is making more of what it does and will do on this and future X-37B flights more public.

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