NASA’s Contingency Plan for Boeing’s Starliner Astronauts
Key Issues with Starliner
Boeing‘s Starliner astronauts, Butch Wilmore and Suni Williams, arrived at the International Space Station (ISS) aboard Starliner in June 2024. However, the spacecraft has encountered propulsion system issues. These problems have raised concerns about its ability to safely return to Earth. Initially, NASA planned a short test mission. However, the technical difficulties extended the astronauts’ stay.
A Boeing spokesperson mentioned that if NASA opts to change Starliner’s mission, the company is prepared to configure the spacecraft for an uncrewed return. Therefore, this potential shift in plans highlights the critical nature of the issues Starliner astronauts are facing.
Propulsion System Challenges Affecting Starliner Astronauts
The Starliner experienced thruster failures during its approach to the ISS in June. Additionally, there were helium leaks used to pressurize the thrusters. As a result, Boeing is conducting an extensive testing campaign to diagnose and fix these issues. The latest test data has revealed new concerns, causing debate within NASA about the spacecraft’s safety for Boeing’s Starliner astronauts.
Decision-Making Process for Starliner Astronauts’ Return
NASA’s Internal Discussions on Starliner
At the time, during a meeting of NASA’s Commercial Crew Program, which oversees the Starliner astronauts project, officials expressed differing opinions on whether to use the spacecraft for the astronauts’ return. For instance, Steve Stich, the program chief, noted that the decision was not clear, with officials raising significant concerns.
Ken Bowersox, NASA’s space operations chief, added that there was no definitive conclusion, reflecting the complexities and risks involved. Consequently, NASA has been granting Boeing additional time to conduct more tests and gather data to build a stronger case for Starliner’s safety for Starliner astronauts.
Potential Use of Crew Dragon for Starliner Astronauts
As a contingency plan, NASA is in discussions with SpaceX to keep two seats vacant on an upcoming Crew Dragon mission for Boeing’s Starliner astronauts, Wilmore and Williams. This plan would be a significant setback for Boeing. It would highlight ongoing struggles in competing with SpaceX’s more reliable Crew Dragon spacecraft, which received NASA approval for astronaut flights in 2020.
Technical Setbacks and Costs for Starliner
Financial Implications for Boeing
Starliner’s development has faced numerous setbacks, both managerial and technical. These setbacks have cost Boeing approximately $1.6 billion since 2016. Moreover, the current test mission alone has cost the company $125 million, underscoring the high stakes involved for Starliner astronauts.
Technical Discoveries Impacting Starliner Astronauts
Recent ground tests revealed that the overheating of Starliner’s thrusters caused Teflon seals to warp. This obstructed propellant tubes and weakened thrust. Consequently, this discovery has increased NASA’s discomfort with relying on Starliner for the return of Boeing’s Starliner astronauts.
Final Thoughts
In August 2024, NASA was still assessing how to bring Boeing’s Starliner astronauts home. The contingency plan discussed a Dragon return in February 2025. Subsequently, Starliner returned without its crew, and Wilmore and Williams joined Crew-9. They ultimately returned on 18 March 2025 after 286 days in space. See NASA’s Crew-9 homecoming report. Therefore, the original February estimate should be read as a historical planning date.
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