NASA’s last-minute decision leaves Boeing Starliner without crew in a dramatic Earth return

Boeing’s CST-100 Starliner spacecraft made a dramatic uncrewed return to Earth on September 6, 2024, following a troubled mission to the International Space Station (ISS). Originally planned as a short eight-day mission to demonstrate Boeing’s capability to safely transport astronauts, the spacecraft instead stayed at the ISS for three months due to a series of technical problems. In a stunning twist, NASA and Boeing decided to bring the spacecraft back without its crew, citing safety concerns. The decision to forego a crewed return has amplified doubts about Boeing’s ability to deliver on its commitment to NASA’s Commercial Crew Program, a project already marred by years of delays and technical difficulties.

Boeing Starliner Faces Setbacks in Space

The Starliner spacecraft launched on June 5, 2024, from Cape Canaveral in Florida, carrying NASA astronauts Butch Wilmore and Suni Williams. However, during its approach to the ISS, one of the Reaction Control System (RCS) thrusters failed, and another malfunctioned by overheating during a critical deorbit burn. While controllers managed to prevent a complete failure through software adjustments, the glitches added to a series of technical mishaps that have plagued Boeing’s Starliner project since its inception.

NASA officials, including Steve Stich, NASA’s Commercial Crew Program Manager, revealed that the spacecraft’s thrusters had experienced overheating, which required real-time software changes to prevent a shutdown. This, coupled with a helium leak issue, led to NASA’s decision to prioritize safety by opting for an uncrewed return. Stich emphasized that the spacecraft’s performance had “exceeded expectations” in some areas but also noted that the decision to bring it back without its crew was “the right call given the circumstances.

A Risky But Necessary Move

NASA’s choice to proceed with an uncrewed return rather than risk a potentially hazardous situation for its astronauts speaks to the severity of the issues encountered. Marking the conclusion of the Crew Flight Test (CFT), the return was crucial for the future of Boeing’s participation in the Commercial Crew Program. Although the spacecraft successfully landed at White Sands Space Harbor in New Mexico, a “bullseye” landing according to Stich, the mission still highlighted critical areas of concern for both NASA and Boeing.

Experts agree that while the safe return was a positive outcome, the series of failures raises questions about the spacecraft’s reliability for future manned missions. This is a setback, no doubt. If Boeing wants to remain a viable partner in NASA’s commercial spaceflight ambitions, they must address these issues comprehensively and quickly.

What’s Next for Boeing’s Starliner?

The Starliner’s issues have added complexity to the future of the spacecraft and its role in NASA’s long-term crewed mission strategy. Boeing and NASA are now focused on addressing the malfunctioning thrusters and helium leaks. Stich has indicated that the next steps involve replacing a faulty seal in the helium pressurization system and modifying the spacecraft’s thermal environment to reduce overheating risks.

The first operational mission of the Starliner, named Starliner-1, has already been postponed from February 2025 to August 2025. As it stands, NASA has yet to decide if another uncrewed test flight will be required to fully certify the Starliner for operational use. This delay also forces NASA to rely heavily on SpaceX‘s Crew Dragon for astronaut transport, at least for the foreseeable future.

Financial Impact and Industry Implications

The financial implications for Boeing are substantial. The company has already reported $1.6 billion in charges against the Starliner program, and that figure is likely to climb as more work is required to address these issues. This jeopardizes Boeing’s competitive position in the growing space industry, particularly against SpaceX, which has been successfully conducting crewed missions for NASA since 2020.

Industry experts speculate that if Boeing does not address these issues quickly and effectively, its partnership with NASA could be at risk. The Starliner program, once seen as a key component of NASA’s strategy to promote competition in spaceflight services, is now on shaky ground. Boeing’s continued technical issues underscore the challenges traditional aerospace companies face when competing with more agile, modern counterparts like SpaceX.

Expert Opinion: Boeing’s Space Future Hangs in the Balance

Space policy expert Laura Forczyk suggests that the stakes could not be higher for Boeing. “The Starliner program is at a crossroads. They must not only fix the current issues but also prove that they can perform reliably and safely. Otherwise, NASA might be forced to reconsider its options for the future.” Forczyk believes Boeing’s deep-rooted history with NASA gives it some leverage, but patience is running thin. The company must show immediate improvement to keep pace with competitors in the NewSpace era.

The Path Forward for Starliner

The next few months will be critical for Boeing and NASA as they chart the path forward for the Starliner program. Changes to thruster designs, thermal management systems, and more rigorous testing are on the horizon. NASA has made it clear that they are not willing to cut corners when astronaut safety is on the line. Until then, the aerospace community and the public will be closely watching Boeing’s steps to fix the Starliner and restore confidence in its capabilities.