Tag: Starliner

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.

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.

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!
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NASA today announced that it has rescheduled the first manned demo mission of Boeing’s Starliner capsule to ISS from February to April, 2023.

The agency attributes the two month delay to scheduling conflicts with other visiting spacecraft at ISS. This might be true, but it also could be that Boeing wanted a little extra time to finish out the work it still needs to do to fix the anomalies that occurred on the unmanned demo mission, as well preparing the new capsule for launch.

This flight will carry two astronauts to ISS for about two weeks. The press release also noted this interesting tidbit:

The previously flown crew module, named Calypso, will be connected to a new service module later this year.

Apparently Boeing has decided to give names to these capsules, like SpaceX has. It also appears that the company and NASA are satisfied enough with the condition of the capsule after flying the unmanned demo flight to use it again for a manned mission.